By applying these DFX methodologies with a focus on cost-effectiveness, medical device companies can extend the life of existing products while minimizing development and production costs.
By applying the DFX methodologies with a focus on cost effectiveness, medical device companies can create products that offer enhanced features, improved performance, or better usability while leveraging existing manufacturing infrastructure, supply chains, and user familiarity. This strategy can help maintain market competitiveness, extend product lifecycles, and improve return on investment for established product lines.
Moreover, by focusing on cost-effectiveness in the redesign process, companies can potentially offer improved products at competitive price points, maintaining or even expanding market share in increasingly price-sensitive healthcare markets.
Let's dive deeper to understand how each design area can be applied to achieve cost-effectiveness when extending the life of an existing medical product design.
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
The following are illustrative examples of a potential product design decisions a company might make to take strategic advantage of the noted benefits of introducing a new product to market vs. updating an existing product. The cases are presented to evoke thoughts and questions around the potential business case for such decisions, and the reasoning behind each.
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Design for Manufacturability (DFM)
Example: For the orthopedic implant with improved materials
A DFM expert could focus on:
- Optimizing the design of the implant for the new material while minimizing changes to existing manufacturing processes
- Identifying opportunities to simplify component geometries without compromising performance
- Adjusting tolerances to reduce machining time and material waste
Cost-effective outcome: Improved product with minimal additional manufacturing investment, leveraging existing equipment and processes.
Design for Assembly (DFA)
Example: For the ventilator with new software features
Working with a DFA expert might involve:
- Redesigning internal component layout to reduce assembly steps for the updated model
- Standardizing fasteners and connections across the product line
- Developing a modular subassembly that can be easily integrated into the existing assembly line
Cost-effective outcome: Streamlined assembly process reducing labor costs and production time for the updated product.
Design for Cost (DFC)
Example: For the pacemaker with extended battery life
A DFC expert could suggest:
- Analyzing the bill of materials to identify components that can be replaced with lower-cost alternatives without compromising performance
- Optimizing the circuit design to reduce power consumption, allowing for a smaller, less expensive battery
- Identifying opportunities for part consolidation to reduce overall component count
Cost-effective outcome: Improved product with lower material costs and potentially reduced manufacturing complexity.
Design for Testability (DFT)
Example: For the surgical robot with advanced instruments
DFT considerations might include:
- Designing built-in self-test capabilities for new features to reduce the need for external testing equipment
- Developing standardized test protocols that can be applied across the product line
- Creating software-based diagnostic tools to quickly identify and isolate potential issues
Cost-effective outcome: Reduced testing time and equipment needs, lowering overall quality assurance costs.
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Design for Reliability (DFR)
Example: For the infusion pump with updated user interface
A DFR expert might focus on:
- Conducting failure mode and effects analysis (FMEA) to identify and address potential weak points in the updated design
- Selecting components with proven reliability to minimize the risk of field failures
- Designing redundancies for critical new features without significantly increasing complexity
Cost-effective outcome: Improved product reliability, potentially reducing warranty claims and service costs.
Design for Serviceability/Maintainability (DFS)
Example: For the surgical robot with advanced instruments
DFS considerations could include:
- Designing new components to be easily accessible and replaceable
- Creating a modular architecture that allows for easy upgrades or repairs of specific subsystems
- Developing improved diagnostic systems to quickly identify and resolve issues
Cost-effective outcome: Reduced service time and costs, potentially extending the product's useful life.
Design for Usability (DFU)
Example: For the infusion pump with updated user interface
A DFU expert might suggest:
- Conducting user research to identify pain points in the current interface
- Designing an intuitive upgrade that minimizes the need for extensive user retraining
- Developing built-in user guidance features to reduce errors and improve efficiency
Cost-effective outcome: Improved user adoption and reduced training costs, potentially increasing product value without significant hardware changes.
Example: For the surgical robot with advanced instruments
DFMo considerations could include:
- Designing a standardized interface for new and future instruments
- Creating a modular software architecture that allows for easy feature updates
- Developing a scalable power and data distribution system to accommodate various instrument configurations
Cost-effective outcome: A more flexible and upgradeable system that can adapt to new requirements without complete redesign, extending the product's market relevance.
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Understanding the Importance of a DFX approach in medical device design & development
Applying Design for X (DFX) methodologies upfront in medical device 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 your medical 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 medical device DFX Project?
Whether you’ve created a new technology, or have an innovative way to use an existing solution, Boston Engineering will turn your ideas into reality. Our experts and Industry Partners will enhance your current team or manage the entire Product Development Process from Market Analysis to Production. Don't leave complex projects or high visibility product launches to chance. Know you're going to get the results you want by working with industry leaders in design, development, and deployment of innovative products driven by Novel Engineering. Contact Boston Engineering Today to get started.
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Impossible Challenge? Try Us.
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.
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