What is Design for Manufacturing or DFM?

PATTY RASMUSSEN| March 24, 2020
WHAT IS DESIGN FOR MANUFACTURING OR DFM?
Design for Manufacturing is the process of designing parts, components or products for ease of manufacturing with an end goal of making a better product at a lower cost. This is done by simplifying, optimizing and refining the product design. The acronym DFMA Design for Manufacturing and Assembly is sometimes used interchangeably with DFM. Five principles are examined during a DFM. They are: Process, Design, Material, Environment, Compliance/Testiing.

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Ditch Witch

Anyone who has ever visited our factory in Perry, Oklahoma, has heard us say it: "We bleed orange."​ But what does it mean? It has something to do with the signature color of our equipment, of course. But mostly it's about what's inside our machines and, especially, what's inside the people who build them.

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Did You Read about the Manufacturing Challenges for 2022?

Article | December 8, 2021

The new manufacturing industry outlook for 2022 is what businesses desire. Due to COVID-19, the sector has seen several ups and downs in recent years. But the industry overcame the most difficult situation by adopting innovations as their working hands. But all this upgrading and digitalization in manufacturing isn't for everyone. Some manufacturers may struggle with this change, while others may not. So, taking into account all industry segments, we have compiled a list of potential manufacturing challenges for 2022. “Many companies simply are not willing to change or think they are done once they make a change. But the truth is that technology, consumer demands; the way we work, human needs and much more are constantly changing.” – Michael Walton, Director, Industry Executive (Manufacturing) at Microsoft The summary of manufacturing industry challenges and industry outlook for 2022 are presented in the stats below. According to the National Association of Manufacturers (NAM), four million manufacturing jobs will likely be needed over the next decade, and 2.1 million will likely go unfulfilled unless we motivate more people to pursue modern manufacturing occupations. According to PTC, 70% of companies have or are working on a digital transformation plan. According to Adobe, 60% of marketers feel technology has increased competitiveness. The statistics show that while digitalization facilitates the process, it also poses several challenges that must be addressed in the coming years. Let's explore what obstacles manufacturers may face in 2022. The Manufacturing Industry Challenges in 2022 The manufacturing business has had a difficult few years as a result of the current economic downturn, and 2022 may not be even that smooth. Thought, technology, and current trends make the operations of upscale manufacturers easier, but not everyone is on the same page. Let's look at some of the manufacturing challenges that businesses will face in the next year. Skilled Labor Shortage The manufacturing industry is facing a workforce shortfall as a skilled generation prepares to retire. Industry experts say that by 2025, there will be between 2 and 3.5 million unfilled manufacturing jobs. As a result of the advancement of new technologies, manufacturing organisations are finding themselves with fewer personnel. They do, however, require individuals with a diverse range of abilities, such as mathematicians and analytic thinkers, to accomplish the tasks with precision. Specific manufacturing tasks have been automated to save time and money. Industry has adopted machine sensors to capture large amounts of data. With this kind of innovation, the industry's job structure is changing and the desire to hire an untrained or trainable workforce is slowly fading in the industry. However, using augmented reality and virtual reality, manufacturers can easily train personnel for the job and save money. Lack of Ability to Mine Data Manufacturing is progressively using IoT. The majority of businesses have already installed or are planning to install Internet of Things machines. These smart machines let businesses collect data to improve production and conduct predictive maintenance. But getting data is a simple task. The difficult aspect is analyzing and aggregating data. Despite possessing the machines, most companies lack the systems to analyze and retrieve the data recorded by the systems. In this way, the industries are missing a vital opportunity. The industry must improve data mining capabilities to make better decisions in real-time. Using IoT for analytics and predictive maintenance is critical. Monitoring technologies can help the sector examine data quickly. It can also help predict an asset's maintenance period. As a result, the industry will move from replacement to predict and fix. Self-service Web Portals That Is Extremely Detailed and Precise Manufacturing businesses usually strive for on-time order delivery and optimum revenue. However, consumer self-service, which has been in the industry for a long time, has never proven to be a simple walk for clients. Clients are frequently required to pick up the phone and contact manufacturers in order to track their orders and receive delivery estimates. This is hardly the service one would expect from a manufacturer, even more so in today's digital era. The term customers in manufacturing include partners, end-users, and subcontractors. These three clients have distinct requirements and concerns about collaborating with the manufacturer. Companies can better serve their customers if their partner and end-customer portals are linked to a central hub which we can mention as self-service web portals. All of the information and updates they need about their orders will be available to them through this new system. They can track, accept and amend their tasks. They'll also use the self–service portal to contact the manufacturer. In this way, manufacturers can better serve their customers. A system like this will ensure that all parties have access to timely information in a digital format. Meeting the Deadline for the Project Product launch timelines are extremely demanding, tight, and stringent. Every project in the assembly line is about cost, time, and quality. Ultimately, these projects are rigorous and well-controlled. Manufacturers who fail to meet deadlines risk losing millions in potential revenues and sales. Due to rigidity and stringent control, companies are less able to change project scopes or make adjustments as projects develop. The majority of initiatives begin with a design commitment. As new facts or change criteria emerge, adjustment flexibility decreases. This can be aggravating for a team that expects high-quality results. Deadlines are always a constraint. Effective Business Digital Marketing Strategy An industry's key digital transformation challenges are driving leads, sales, and MRR through digital channels. Many manufacturing organizations struggle to efficiently use marketing channels like paid media, enterprise SEO, local SEO, content strategy, and social media. In our opinion, one of the most significant issues these organizations have is their digital experience, website design, and overall brand presentation. They can't ignore them if they want to keep enjoying the manufacturing revival. Visibility of the Supply Chain Manufacturers must respond to the growing demand from customers for greater transparency. In order to meet customer demand across the customer experience and product lifecycle, they must first understand that precise and real-time visibility throughout the supply chain is essential. All details must be taken into consideration by the manufacturers. They must be aware of any delays in the arrival of products on the market. Keeping abreast of such developments would give them a leg up in terms of adjusting or rectifying the situation. Final Words Manufacturing industry challenges have long been a part of the industry. However, industry leaders and professionals have always confronted and overcome any challenges that have come their way. The year 2022 will also be a year of achievements, setting new records, and growth for the manufacturing industry, since it will be a year in which it will develop solutions to all of the aforementioned challenges. FAQ What is the future of manufacturing? Manufacturers should start using AI, block chains, and robotics today. The combination of these new technologies will reshape manufacturing. A new workforce capable of augmenting these technologies is developing and will become the future of manufacturing. How will automation affect manufacturing in 2022? When applied properly, automation can greatly assist manufacturing. These benefits include shorter production times, faster and more efficient work than human labor, and lower production costs. How is the manufacturing industry’s market likely to upsurge in the future? According to BCC Research, the global manufacturing and process control market is expected to grow at a CAGR of 6.3 percent from $86.7 billion in 2020 to $117.7 billion in 2025. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is the future of manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Manufacturers should start using AI, block chains, and robotics today. The combination of these new technologies will reshape manufacturing. 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Lead Generation for Manufacturers: 5 Effective Techniques That Work

Article | January 4, 2022

Lead generation for manufacturers has always been tough due to a lack of knowledge about new technology and trends that can help them generate more business leads. There are still a lot of small and mid-sized manufacturing companies that rely on antiquated manufacturer lead generation methods. In this article, we'll discuss some proven methods for generating leads that can help you increase your company's sales and improve your overall return on investment. "Don’t think of your lead as "LEADS." Instead, think of them as people who are frustrated because understanding and buying your product is too hard. Your job is to make it easy for them to learn about your product and get started. " —Andy Pitre, VP of Product, HubSpot So let's get started. Factors That Must Be Aligned to Drive New Business Leads Landing Pages Landing pages are mini-websites embedded into your site. To deliver an experience that speaks directly to the user's intent, marketers use landing pages. Create unique landing pages for every industrial lead generation campaign. Calls-To-Action To generate quality leads, you need to have a strong call to action (CTA). CTAs are usually buttons that allow users to submit information, visit a landing page, or download an e-book or white paper. Your CTA must be compelling. Give your prospects a reason to click and remove any barriers to the click. CTAs should be bold, high-contrast, and easily identifiable. Forms Without forms, it is impossible to collect leads. Therefore, visitors will be asked to fill out forms that collect their contact information in exchange for an offer. Offers Every lead contains a transaction. A company provides a valuable service in exchange for a prospect's contact information. You won't get many leads unless you provide value to your potential customers. This offer comes in the form of an e-book, consultation, coupon code, or whitepaper. To generate more leads, make compelling offers. Website The above components can't exist if you don't have a website. If you want to emphasize your business, you need to generate quality leads. Why? Because most of today's B2B buyers are millennials, who are highly tech-savvy and increasingly conduct their supplier research online. How to Generate Manufacturing Leads: 5 Effective Techniques Create a Website That Converts "The lead generation process starts by finding out where our target market ‘lives’ on the web." – Wayne Davis Your website should be a trusted source of quality leads. Unfortunately, many companies lose sight of this and develop websites that are cumbersome and difficult to browse, causing a rift between you and your potential customers. Don't expect people to behave if your site doesn't encourage them to act. Your website should have clear "call to action" buttons and lead capture options that allow visitors to contact you in a simple and pleasant way. Additionally, there are website optimization tools available, including PageSpeed Insights, Hotjar, Google Optimize, and WAVE. All of the above-mentioned website optimization tools provide complimentary services. So, this is the most accessible and most reliable approach to generating web leads. Make Descriptive Infographics Infographics are a great way to provide prospects with helpful information while motivating them to contact you. Most importantly, infographics establish your company as a thought leader and unconsciously identify you with industry authority. According to recent surveys, Nearly 41% of respondents indicated that infographics and illustrations are the most effective solutions for achieving their business objectives. On social media, infographics receive three times the number of shares as other types of content. Articles that included infographics received 72% more views than standard articles. A great infographic has a great design. If your organization lacks an in-house graphics team, you can simply locate a freelance designer to create a stunning infographic for you. Your infographics are ageless pieces of material that can be reused for smart marketing and lead generation manufacturing. Here's an example of an infographic from Digital Marketing Philippines from 2019 that received over 1,600 shares and is jam-packed with data and text. In this way, you can see how the company may have gotten its leads from these 1600 shares, each of which is a potential customer. Host an Event According to Bizzabo, 86% of senior management (Senior Managers, Executives, and Board Members) believe that in-person events are critical to the success of their company. The majority of B2B marketers (97%) believe in-person events have a significant impact on achieving business goals. According to Marketing Charts, 68% of B2B marketers agree that in-person events aid in lead generation for manufacturers, while case studies help with lead conversion and acceleration. Improve manufacturing lead generation through events that can occur both online and offline. Organize any kind of event to attract your target market while collecting contact information. Use live events to interact with consumers in real-time, answering questions, addressing objections, learning about your audience, and guiding prospects through the sales funnel. Consider webinars, workshops, seminars, meetups, and conferences. Create a Value-Packed Newsletter "Content is the fuel for your lead generation efforts." – Dayna Rothman According to the Content Marketing Institute, 31% of B2B marketers believe email newsletters are the most effective way to nurture leads. 81% of B2B marketers report that email newsletters are their most frequently used form of content marketing. Create a must-read newsletter that invites interested prospects to engage and remain connected with your company. This enables you to stay top-of-mind with consumers and promote your products and services to move prospects along the sales funnel. The newsletter can have new blog entries, product or service updates, special deals, upcoming events, and recommended reading from other thought leaders. Incorporate SEO into Your Marketing Plan According to Intergrowth, 61% of B2B marketers say SEO and organic traffic generate more leads than any other type of marketing. Search engine leads convert at a rate of 14.6%, while outbound leads (cold calling, direct mail, etc.) convert at a rate of 1.7%. Manufacturers are no exception when it comes to the importance of search engine optimization (SEO). As a result, you may generate many leads with the correct marketing approach and a profound grasp of SEO for manufacturers. Final Words When we consider the statistics explained earlier in this article, we can see the benefits of all of the techniques mentioned and how they can help you increase your lead generation and, as a result, your overall business ROI. Thus, we can refer to the above-mentioned lead generation techniques as sales-driven strategies that will assist you at every lead generation and conversion stage. Improved lead generation for manufacturers enables businesses to reach a vast customer base and generate more high-quality leads. FAQ What is a high-quality lead in manufacturing? Leads of high quality have an increased propensity to convert into paying consumers. The more qualified your leads are, the more likely they will buy your product or service. What are the lead generation challenges? Making accurate data, shaping conversations, and converting qualified leads into sales are some of the significant challenges in manufacturing lead generation.

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Business Models for Sustainable Manufacturing

Article | December 23, 2021

Sustainable business strategiesare bringing significant financial and environmental benefits to manufacturers. Sustainable manufacturingcreates goods while minimizing environmental consequences and preserving energy and natural resources. In addition, sustainable production improves the safety of workers, the community, and the products they produce. Allied Market Research projects that the worldwide renewable energy market will reach $1,977.6 billion by 2030, increasing at an 8.4% CAGR. As a result, we can conclude that many businesses are transitioning from traditional manufacturing to sustainable manufacturing. It’s a good time to be a part of the renewable energy industry. New technologies are coming to market every day, and we work in an industry that is trying to solve an enormous challenge. – Susan Stone, Chief Executive Officer at Ubiquitous Energy, Inc., in conversationwith Media 7 Though many organizations are pioneering the sustainable manufacturing approach, we have selected five of the most well-known companies making serious attempts to be sustainable manufacturing companiesby all means. In addition to the list of sustainable manufacturing businesses, this article will discuss the advantages of sustainabilityand how organizations may become carbon neutral. So let's get started. Top 5 Companies with a Sustainable Business Model The following are five manufacturing businessesthat are investing in sustainable manufacturingmethodsacross their production processes to become more responsive to our mother earth. Philips Electronics The company is reducing its environmental effect by engaging with suppliers, taking climate action, and driving the shift to a circular economy. Climate change is a key concern for Philips. So they are rethinking their business strategies and decoupling economic development from environmental and social impacts. They met their aim of becoming 100% carbon-neutral in their operations and procuring 100% of their power from renewable sources by 2020. They intend to obtain over 75% of their total energy usage from renewable sources by 2025 and to reduce CO2 emissions across their whole value chain to meet the 1.5°C global warming state. Schott Sustainability is profoundly embedded in SCHOTT's DNA. It derives from their distinctive business concept, which dates back to 1896. Their sustainability plan includes responsible governance, workers, society, environment, and climate. “Regarding climate change, it is high time to act. Everyone must take responsibility – politicians, companies and society. We are ready to play our part. We want to become climate neutral by 2030.” - Dr. Jens Schulte, Member of the Board of Management with responsibility for the “Zero Carbon” strategy program Long-term thought and responsible behavior are guiding principles of SCHOTT, which is why they care about the environment and climate. They are entering a new era of sustainable management with their “Zero Carbon” strategic program. Long term, they seek to eliminate fossil fuels as soon as technologyallows it. They are focused on the most energy-intensive stage of glass melting to create new solutions. IKEA IKEA's low-cost furniture utilizes a lot of wood. But because the company employs sustainable forestry practices, your new minimalist nightstand didn't cost the globe a rainforest. The business is also investing heavily in solar and wind energy. This year, the corporation intends to increase its already significant expenditures in renewable energy, to reach 100% clean energy by 2020. It also leads in offering cleaner, greener products. Nike In addition to encouraging people to walk, this footwear manufacturer uses recycled aluminum frames in its headquarters in the Netherlands, and underground energy storage to reduce its carbon footprint. Moreover, it has implemented stringent emission regulations at all of its manufacturingfacilities and has cut its overall carbon footprint by around 80 % since the late 1990s. The company also sells the most environmentally-friendly soccer sneakers on the market. Johnson & Johnson According to the company, Johnson & Johnson has just begun transitioning a significant portion of its energy reliance to solar power in an effort to become the world's most socially responsible organization. Currently, it is the second-largest user of solar energy in the United States, with more than half of its power coming from environmentally friendly sources. Rewards of Adopting Sustainable Manufacturing Practices Many businesses are seeking sustainabilityfor many reasons, including: Reducesoperating expenses and waste Respondsto new consumers and get a competitive edge Buildspublic trust and protect brand and reputation Createslong-term business viability Recognizesand address regulatory constraints What Can We Do to Make Sustainable Manufacturing a Reality? Every business must support green energy projects. Here are some fundamental actions that every business should take to transform itself into a sustainable manufacturing organization. Maximize the Efficacy of Fossil Fuels In today's society, energy conservation is a win-win situation. Approximately half of the world's known oil reserves have been exhausted, which means we are near to the point of diminishing returns in terms of supply. As far as we know, there hasn't been a shortage of supplies. Shutting down unwanted equipment might help you save money immediately. Replace a single-speed motor with a variable speed or servo drive. Use a hydraulic pump with variable speed. Wind, solar, and hydropower can also be used to conserve energy. Reduce or Eliminate Waste Don't overindulge; merely take in what you need to get the task done. At this point, we may all agree that it's easy, but in the past, our primary focus was on reducing productioncosts or time to market. Whether we were wasting resources was unknown or irrelevant to anyone. Metal, paper, and packaging are all examples of industries where this is true. The potential for waste reduction may justify the purchase of highly accurate production equipment. Recycle As a byproduct of manufacturing, metals may be easily recycled and used for new products. In addition, recycling metal saves money and energy since it uses less energy in the manufacturing process, allowing for a 60 % or more reduction in the energy needed to make new products. Final Words Sustainable manufacturing practicesare making manufacturing industries more socially responsible and carbon neutral. This new manufacturing method is necessary for today's period because we must consider future generations while improving today's. Natural resources must be conserved before depleting, and we have nothing left to offer future generations. Responsible organizations have already used this sustainable approachin their manufacturing processes, and we anticipate that every company should consider this method to be more sustainableand environmentally responsible. FAQ What is the difference between green and sustainable manufacturing? The main difference between green and sustainable is that green addresses a single aspect i.e., environmental health, but sustainability addresses the entire system, including economic, social, and environmental aspects. Which business is more environmentally friendly? According to Corporate Knights, Alphabet, Tesla, and AstraZeneca were among the world's most sustainable companies in the Global 100 Index for 2021. What are the four sustainability factors? The word sustainability refers to programs, activities, and actions to preserve a resource. But it relates to four unique key areas. Human, social, economic, and environmental are the four pillars or factors of sustainability.

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The 2022 Manufacturing KPI Checklist Should Include These Five Indicators

Article | December 23, 2021

Every manufacturing company aims to be as efficient as possible to maximize profit. However, it's difficult to determine where you stand and what targets to establish unless you can precisely measure your efficiency. Manufacturing KPIsplay an important role in this process. Keeping track of many indicators without considering their commercial worth is a waste of time. “Not everything that can be counted counts and not everything that counts can be counted” - Albert Einstein But connecting goals to measurements is a certain way to track progress and improve processes. So let's get started with how to choose the most appropriate key performance indicators(KPIs) for your business. Manufacturing KPI 2022: How to Choose the Right One? Why are KPIs called “Key” Performance Indicators? While any statistic can be used to assess performance, KPIs are the most critical. Hence they are called key performance indicators. Companies' priorities while selecting their company KPIs may differ substantially depending on the industry in which they operate. “Strategic-operational KPIs alignment gives the organization a powerful tool to use when implementing change.” ― Pearl Zhu A corporation should not track more than ten manufacturing KPIs to avoid overblowing processes. So, manufacturing efficiency, customer satisfaction, lead times, etc., should all be included. Depending on your business nature, you must select your KPIs. However, each of those indicators must meet a set of criteria before being considered meaningful. So, what is a decent KPI for manufacturing? It gives objective and clear data on progress toward a certain goal It measures efficiency, quality, punctuality, and performance It allows for tracking performance over time It helps in decision making It should be the one that matches the company's long-term objectives It has to be measurable and quantifiable It must be realistic and actionable Following that, let's have a look at the most important manufacturing KPIs for 2022, which will assist you in better understanding your manufacturing business and formulating a growth strategy in line with that understanding. Most Critical Manufacturing KPIs in Order of Priority Despite the fact that manufacturers should also monitor general key performance indicators (KPIs) such as sales revenue, net profit margin, and so on, the manufacturing business demands the tracking of specific manufacturing metrics. Below are some of the most important manufacturing key performance indicators (KPIs). Work-in-process Using this manufacturing KPI metric, you can see how much value there is in products still in progress. It assists manufacturing organizations in determining how much of their working capital is locked up in incomplete products and can aid in identifying supply chain managementdifficulties. You can compute the Work-In-Progress (WIP) by using the formula provided below. Return on Assets This manufacturing KPIseems to be more about financing than manufacturing. Yes, it does. However, financial measurements are just as vital as production ones. A firm cannot exist unless it generates revenue, and this indicator measures how efficiently your company uses its assets and generates revenues. The Return on Assets (ROA) of your company can be calculated using the formula below. Cost Per Unit It is critical to understand the overall manufacturing cost per unit. You can't appropriately price a product without it. This manufacturing KPIdivides total manufacturing costs by the number of units produced. Materials, overhead, depreciation, and labor are standard costs. Demand Forecasting Companies utilize this manufacturing statisticto forecast future raw material needs to satisfy client demand. Unfortunately, this statistic is more challenging to employ because it is mainly dependent on unpredictable external circumstances. The basic formula is: Where: The seasonal factors are distinct Average demand is calculated as: Lead Time A company's lead time, also known as order cycle time, is an important KPI. It shows how swiftly your organization processes orders and meets client requests. It is time it takes to complete an order from confirmation to delivery. Long lead times can imply process inefficiencies that produce bottlenecks and excessive expenses. Conversely, short lead times are important since they allow you to respond to consumer needs swiftly and efficiently. The total lead time can be divided into smaller segments as follows: The time it takes to manufacture a product from start to finish The time it takes to deliver a product from stockto a client The time it takes suppliers to deliver products to manufacturers By segmenting the lead time, you may more precisely identify the areas where inefficiencies in the process occur. Toyota’s Four Key Performance Metrics As a company, Toyota places a high focus on environmental protection. Toyota's vehicles are designed to use less fuel and produce less waste. Regardless of the company's size, Toyota is committed to protecting the environment. Toyota's 'Earth Charter' was created in 1992 as part of the company's Global Policy initiative. It was Toyota's first overseas facility and the UK's first ISO14001-certified car manufacturer. Waterborne paints were utilized for the first time and zero waste was sent to landfills. In 2009, Toyota Manufacturing UK did not use any incinerators. Toyota has developed a set of key performance indicators (KPIs) for each of its major production areas. There are four key performance metrics: energy, water, waste, and volatile organic compounds (VOCs). Since its start in 1992, Toyota Manufacturing UK has attempted to mitigate its environmental impact. The figure below illustrates the environmental KPIsfor the Burnaston plant. Each year, Toyota sets new goals to improve its results. 79% reduction in vehicle energy consumption 62% reduction in waste per car 76% reduction in VOC emissions per car 79% reduction in water consumption per vehicle Final Words You can use the aforementioned manufacturing KPIsto construct your manufacturing KPI template, but keep in mind that the manufacturing metricsyou need to track may differ from those listed here. The first prudent move any business can make while examining its operation is to identify and track the relevant KPIs. Also, in manufacturing, there are several different KPIs, phrases, and abbreviations need to be understood and used where it makes the most sense. FAQ What is manufacturing KPI? A manufacturing Key Performance Indicator (KPI) or metric is a well-defined and measurable indicator that the manufacturing sector uses to evaluate its performance over time and compare it to that of other industries. What are the key KPIs for manufacturers? On-Time Delivery, Production Schedule Attainment, Total Cycle Time, Throughput, Capacity Utilization, and Changeover Time are some of the key manufacturing KPIs.

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Spotlight

Ditch Witch

Anyone who has ever visited our factory in Perry, Oklahoma, has heard us say it: "We bleed orange."​ But what does it mean? It has something to do with the signature color of our equipment, of course. But mostly it's about what's inside our machines and, especially, what's inside the people who build them.

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