Technological Solutions that Simplify Design for Manufacturability in Reshoring

Simplifying product design is one of the most impactful strategies for making reshoring a cost-effective and sustainable investment.

By optimizing designs for manufacturability, companies can reduce production complexity, lower costs, and ensure compatibility with domestic manufacturing processes. However, achieving this requires a strategic approach and the right technological tools. 

At Boston Engineering, we specialize in helping businesses integrate cutting-edge technologies into their product development and manufacturing processes. This blog explores actionable solutions to address the key questions asked in Simplifying Design for Manufacturability (DFM) and provides insights for executives concerned about costs and long-term viability. 

Continue reading below to learn more

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

Impacts and Strategic Responses from the Boston Engineering founders. Whether you’re facing workforce shortages, navigating policy changes, or striving to modernize your operations, this conversation offers concrete solutions to tackle today’s challenges and position your business for long-term success.

The re-shoring trend is transforming the way product companies think about their supply chains and manufacturing strategies. What began as a response to rising labor costs and geopolitical risks has accelerated in the wake of the pandemic, revealing vulnerabilities in global supply chains and prompting companies to reevaluate their sourcing, production, and distribution models.

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

In this interview, Boston Engineering’s founders, Mark Smithers (Chief Technology Officer) and Bob Treiber (President), share insights into the key drivers behind re-shoring, the real-world challenges, and how companies can adapt to take advantage of the changes.

Drawing from decades of experience in defense, medical, and commercial sectors, they explore the practical implications of re-shoring for operations executives, product managers, and C-suite leaders alike.

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

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Why Simplifying Design for Manufacturability is Critical for Reshoring 

Simplifying designs reduces the labor and material requirements of production, making domestic manufacturing more viable. Additionally, streamlined designs improve scalability and enhance product quality, ensuring long-term operational efficiency. 

Key Question 1: Can the Product Design Be Simplified to Reduce Material Costs and Assembly Time? 

Simplifying a product design involves reducing the number of parts, materials, and processes required for assembly. 

Technological Solutions 

• 3D Printing for Rapid Design Iteration 

• • What It Does: Enables rapid prototyping and testing of simplified designs. 

• • How It Helps: 

• • • Reduces the time and cost of physical prototyping. 
    • Allows quick evaluation of new design concepts to identify the simplest and most cost-effective option. 

• • Example: A consumer electronics company uses 3D printing to prototype a simplified housing design that eliminates screws and uses snap-fit features, reducing assembly time significantly. 
    
    
• Topology Optimization Software
  
  
  • What It Does: Uses AI to optimize the geometry of components for strength and material efficiency. 
    
    
  • How It Helps:  

• • • Minimizes material usage while maintaining structural integrity. 
    • Identifies areas where components can be consolidated or thinned. 
      
      
  • Example: A medical device manufacturer reduces material costs by using topology optimization to redesign a complex frame into a lightweight structure with fewer materials. 
    
    
• Value Engineering Tools 

• • What It Does: Analyzes design elements to identify features that can be eliminated without compromising functionality. 

• • How It Helps: 

• • • Focuses on simplifying designs to meet essential performance requirements. 
    • Identifies unnecessary features that drive up costs. 

• • Example: A packaging equipment manufacturer reduces complexity by eliminating decorative but non-functional design features, streamlining assembly processes. 

Key Question 2: Are There Opportunities to Use Standardized or Locally Sourced Components?

Standardizing components reduces costs by increasing compatibility with existing manufacturing capabilities and improving scalability. 

Technological Solutions 

• Component Database Integration
  
  
  • What It Does: Provides access to libraries of standardized components. 
    
    
  • How It Helps: 
    
    
    • Allows engineers to replace custom parts with off-the-shelf alternatives. 
    • Ensures compatibility with local suppliers and reduces lead times. 

• • Example: A defense contractor replaces custom fasteners with standardized ones from a domestic supplier, reducing procurement costs and delays. 
    
    
• Bill of Materials (BOM) Analysis Software
   
  • What It Does: Analyzes BOMs to identify opportunities for part standardization and local sourcing. 
    
    
  • How It Helps:
     
    
    • Highlights redundant or specialized components that can be consolidated. 
    • Reduces costs associated with managing a diverse inventory. 
      
      
  • Example: An automotive parts manufacturer reduces complexity by consolidating 10 variations of a fastener into one standard type. 

• Supplier Collaboration Platforms 
  • What It Does: Facilitates communication and collaboration with local suppliers to identify compatible components. 
    
    
  • How It Helps:
     
    • Simplifies the sourcing process by connecting designers with vetted suppliers. 
    • Ensures that components meet quality and compliance standards. 
      
      
  • Example: A consumer goods company uses a supplier platform to identify locally sourced materials that align with their sustainability goals. 
  
  
  

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Key Question 3: How Can Assembly Processes Be Simplified to Align with Domestic Manufacturing Capabilities? 

Simplifying assembly processes reduces production time and labor costs, making domestic manufacturing more viable. 

Technological Solutions 

• Design for Assembly (DFA) Software
  • What It Does: Evaluates product designs for ease of assembly and provides recommendations for simplification.
  • How It Helps:
    • Identifies components or steps that can be eliminated.
    • Provides insights into how products can be assembled using robotics or automation.
  • Example: A furniture manufacturer uses DFA software to redesign a chair with fewer parts and tool-free assembly, cutting assembly time. 
    
    
• Process Simulation Tools
  • What It Does: Simulates manufacturing and assembly processes to identify inefficiencies.
  • How It Helps:
    
    
    • Visualizes how designs will interact with manufacturing equipment.
    • Identifies bottlenecks and suggests process improvements.
      
      
  • Example: A consumer electronics company uses process simulation to optimize robotic assembly of circuit boards, increasing throughput.
    
    
• Augmented Reality (AR) Assembly Training
  • What It Does: Provides real-time guidance for assembly workers using AR headsets.
    
    
  • How It Helps:
     
    • Simplifies onboarding for new employees.
    • Reduces errors by providing step-by-step instructions for complex tasks.
      
      
  • Example: A medical device manufacturer trains employees on simplified assembly processes using AR, cutting error rates. 

Conclusion: Build for Long-Term Success

Simplifying designs for manufacturability is essential for reshoring success, reducing costs while ensuring compatibility with domestic production. By leveraging advanced technologies and streamlining processes, companies can achieve sustainable growth and long-term operational efficiency. 

At Boston Engineering, we specialize in providing the tools and expertise needed to simplify designs and optimize manufacturing processes for reshoring. 

Contact us today to learn how we can help you simplify your product designs and build a smarter, more cost-effective future for your business.  

How Boston Engineering Can Help  

At Boston Engineering, we bring decades of experience and advanced technological expertise to help businesses simplify product designs for reshoring. Here’s how we can assist: 

• Design Assessments: Analyze your current designs for opportunities to reduce complexity and improve manufacturability. 

• Technology Integration: Implement tools like DFA software, topology optimization, and process simulation to streamline design and production. 

• Supplier Collaboration: Help identify standardized and locally sourced components to reduce costs and improve scalability. 

• Assembly Optimization: Redesign products to align with domestic manufacturing capabilities, including automation and robotics. 

Boston Engineering: Your Partner in Reshoring Success 

Product redesign is a critical step in reshoring that ensures compatibility with domestic manufacturing, reduces costs, and enhances efficiency. By conducting a thorough evaluation and leveraging advanced tools, companies can unlock the full potential of reshored production. 

At Boston Engineering, we specialize in guiding businesses through this process, offering tailored solutions that align with your goals and capabilities. 

Let’s work together to shape the future of American manufacturing—one innovative solution at a time. 

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