This is the first in our Reducing Medical Manufacturing COGS series detailing how KMC Systems reduces customer Cost of Goods Sold during the medical device manufacturing process through its design-for-manufacturability software. The DFMA® software is just one aspect of KMC's cost-saving Design for X (DFx) process.
KMC Systems reduces your medical device manufacturing costs through should-cost analysis using our Design for Manufacture and Assembly (DFMA®) software.
|KMC Systems Mechanical Engineer Will Brooks uses the DFMA® software to reduce the cost of a manufactured medical device part.|
The Boothroyd Dewhurst DFMA® software we use combines Design for Manufacturability (DFM) with Design for Assembly (DFA) capabilities.
KMC engineers use the DFMA® software's built-in should-cost tool to evaluate their designs and reduce the cost of medical product parts.
KMC Systems Mechanical Engineer Will Brooks explains:
The tool has a number of capabilities, but one of the main ways we use the tool is to analyze the costs associated with manufactured custom parts. By knowing every detail and operation of how a part is made, along with the cost associated with every feature, you can figure out what a part “should cost”.
Brooks says that by performing the should-cost analysis on some of the more costly and complex parts, KMC determines:
- a better or cheaper way to manufacture the part
- if the vendor mark-up or cost is too high
- if there are unnecessary tolerances or features in the part that add cost
- if a redesign is needed
"These are just a few of the takeaways we often have after an analysis," Brooks said. "With this professional should-cost software tool, we are also able to develop accurate, organized data on custom manufactured parts. This allows us to start intelligent discussion with our suppliers regarding the manufacturing process and costs of our parts."
KMC Business Development Manager and Mechanical Engineer, Bob Evans explains that having these intelligent discussions with suppliers allows KMC to find the most cost-effective solutions for its medical manufacturing customers.
Evans said the method and materials used to manufacture a medical device's parts directly affect the cost of the product.
Design for Manufacturability often involves part count reduction, through combining parts, to improve functionality and reduce the amount of materials used. Understanding the design options for each medical device component empowers KMC to find the right fabrication and molding resources, and to collaborate with them effectively.
Medical Design Technology Magazine's Designer-Molder Collaboration Streamlines Device Production article, by Director of Operations for Rogan Corporation Jim Ritzema, states:
It is the nature of the medical device market that has proven each device has its own unique challenges, some involving the physical design itself and some involving the choice of the most appropriate materials. In each case, investing time in collaborative discussions with a knowledgeable molder will pay dividends in making the best, most informed choices, leading to a successful product in the marketplace.
Design for Assembly addresses how the parts fit together, which goes hand-in-hand with the
lean manufacturing principles that KMC implements. KMC implements the lean method of poka-yoke, Evans says, by designing and manufacturing parts so that it's impossible to put two parts together the wrong way. Designing your medical device part in a way that prevents user error saves time, money and malfunction.
KMC implements the Design for X (DFx), also known as Design for Success, process throughout each stage of the medical product life cycle.
According to a Medical Design Briefs article on DFx:
The ability to design for successful execution of product, project, and business objectives is more critical than ever in a medical device market with increasing expectations on quality and overall cost. Effective DFx practices rely on a solid understanding of big-picture goals, intentional DFx planning and disciplined design execution, and effective leveraging of diverse and experienced people throughout an organization.
KMC recognizes your need for cost-effective and high quality medical device manufacturing. Evaluating our designs with Design for Manufacturability and Assembly software is just one way we reduce your Cost of Goods Sold while maintaining the highest quality standards.
The next post in our Reducing your COGS series details KMC's process for manufacturing more cost-effective parts for your medical device.