VersaCross:

Future proofing to save time

Molding: mitigating risk
Cheaper vs quality
 Vendor management and communication
o Supplier validation (understanding supplier capabilities)
o “we think we can do it”
 Confirming in writing
 Steel-safe changes

IM part design
 Over-molding
 Looking at other products for reference

Machining
 Avoiding the Pulform tools situation
 Matching product tolerancing with tooling/vendor capabilities
 Fits and tolerancing
o Redundant machining

Design transfer timing

 Transfer before first-offs
 FAI timing

Process feasibility
 Working with process to validate manufacturing processes
 Validating product assembly

GD&T

Sheath:
- Process development before design V&V
- Better knowledge of IM process
o Incorporating mold flow analysis to part design
o Better understanding of mold analyses
- DFM process is not always conducted
o If design works, DFM is not considered
o Can we manufacture the design reliably?
o Identifying basic/minimum process capabilities, yield, PPK, CPK, etc.
o Usually design is fixed and process is tweaked to make things work
o 90% of design is complete before process is started
o Manufacturability consideration before design is frozen
o No time given to process development
- No DFM requirements in D&D process

- Tooling design
o Knowing how things are made
- Material selection

- Identifying high risk/long turnaround manufacturing processes

o And de-risking

- Hitting tights tolerances in IM parts

o Cutting steel-safe
o Using prototype molds

Generator:
- Considering end-of-life
o Training on product life cycle
o Program the analyses design and identifying replacement components
o What replacements are there for components (capacitors, etc..)
o More sustainable design
o Components reaching end-of-life and requires design change
 Can this be avoided through DFM

- PCB design/circuit board design

o You can pack everything, but that might not be great for design
 Serviceability, assembly, possible design changes, upgrading/changing components that have
different footprint

- Identifying high risk/long turnaround manufacturing processes

o And de-risking
o Identifying Long-lead time sole source components.

- Custom cables for duo mode – cable for transferring between generator and imaging device
o Cable not commercially available
o Resulted in a supply-chain-issue
o If possible no-sole sourcing
o Designing strain relief that are easy to manufacture
 Press fit type rubber, but what other methods are there that are more efficient to make?
 Is your design scalable
 When you do V&V, do it with operators as much as possible
 Are the operators going to have any issue?

- Collaborating with other teams on designs, ie. tolerances, can machinist make them?

- Ability to design for wider tolerance range, if possible

- Usability testing, for assembly and device functionality