DFX Considerations: Defining Cost and Volume Targets

Understanding the anticipated production levels, both annually and over the full product lifecycle, is essential for aligning the design with the most cost-effective manufacturing processes and techniques.

A critical early step in any new product development effort is to clearly define the cost and volume targets that will drive the design process. For example, if you're developing a product expected to have annual volumes of 100,000 units or more, your design should heavily prioritize manufacturing methods like plastic injection molding and metal stamping.

These processes become highly cost-effective at higher production scales, allowing you to achieve aggressive cost targets. On the other hand, for low-volume products, simpler and more flexible fabrication approaches may be more appropriate.

Read more below.

The focus and discipline of DFX is a powerful tool if used as part of a broader strategic approach to developing product/process differentiation, and a sustainable advantage against competition. Involve Design for X in Strategy. Once your team has determined the focus of your strategy, place the focus of design on developing competitive advantage. 

At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:

• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Design for Cost (DFC)
• Design for Testability (DFT)
• Design for Reliability (DFR)
• Design for Serviceability/Maintainability (DFS)
• Design for Usability (DFU)
• Design for Modularity (DFMo)

Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X

Defining Cost and Volume Targets for Your Product Design

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Beyond just the production volumes, it's also critical to consider the regulatory environment and any unique requirements related to the intended application. For medical devices, you'll need to ensure the design aligns with the relevant regulatory bodies and potential reimbursement models. Similarly, harsh or specialized operating environments may call for the use of more durable materials and components.

Carefully defining these cost and volume parameters upfront provides a crucial guidepost for all downstream design decisions. It allows the team to make informed tradeoffs and optimize the product configuration for manufacturability and profitability. Overlooking this foundational step can lead to designs that are simply not viable from a commercial standpoint.

So as you embark on your next new product development initiative, be sure to invest the time required to clearly establish the core cost and volume targets. This will help ensure your design efforts are laser-focused on creating a successful, market-ready product.

Learn more about Additive Manufacturing in the Design for X Space in this excerpt from 
the Boston Engineering 2024 Technology Outlook. Written by Frank Silveira, Boston Engineering's Vice President of Engineering, this piece explores areas of continued growth in Additive Manufacturing to support Design for Assembly (DFA) and Design for Serviceability and Maintainability (Among Others). Read Now

 Understanding the Importance of a DFX approach

Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.

Do you offer training on DFX for engineering teams?

Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio. 

Ready to Begin your next DFX Project? 

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Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.    

The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace.  Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.