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David A. Waliszewski, P.E., CPIM

Want to Learn How to Lower Product Costs

Schedule onsite training tailored to your company’s needs

+1 (510) 928-0690 or email Dave@pdfm.info

Product Design for LEAN Manufacturing and Assembly

Are new product costs under target and less than the competition?

The Design for LEAN Manufacturing and Assembly Class* charts a direct line through the causes that account for 80% of the excess cost in products and how to eliminate them. The class provides design check lists for engineers to follow to achieve the best results; then real world examples show how following the check lists produce the best results. Special emphasis is given on how to combine parts, reduce part count and lower total cost. Presented are unique concepts of how to design parts to leverage manufacturing processes to achieve extraordinary cost savings. Learn how to design lower cost parts and assemblies for LEAN Manufacturing.

An engineer used one check list from the combining parts section of class to redesign a typical approach used in the company. The new design resulted in a $22,000 annual cost savings.

*Details about time frame and training option for each class is on the Class page.

New product development time faster than the competition and technology?

The New Product Introduction Class* provides a proven method for new product develop, covers how to create product support teams, manage new product development projects to be on time, at cost and deliver products to market faster.

Are engineering changes implemented well and lowering product costs?

The Engineering Change Class* covers ECO fundamentals, how engineers should process ECOs, how to reduce cost in existing products while processing ECOs, how to obsolete products and best practices in managing the ECO process.

A Quality Management VP whose company implemented the Engineering Change process learned in class claims company savings in excess of $2 million annually.

Does the delivery time for make to order products beat customer’s expectations?

Make and Engineer to Order (MTO/ETO) Products are covered and how to reduce engineering time & content while reducing product cost and time to market.

A company president of a make to order products company estimated the product design changes combined with the new assembly processes resulted in annual cost savings of $5,000,000 and reduced product time to market by 75%.

Want to lower the assembly cost of your products? Ask a person who knows what drives assembly costs and knows how to design an assembly process for the lowest costs, assemble products in the shortest time with a process that can flex to meet changing market demands when needed.

Want to lower fabricated parts cost in your products? Ask a person who knows how manufacturing processes work, what drives process costs and knows how to take advantage of the process to lower costs.

David presents unique concepts on how to design to leverage manufacturing processes to achieve extraordinary cost savings.

A senior manufacturing company executive told David, his concepts of leverage has taken design for manufacturing to a new level of how to lower product costs.

Design theories are not discussed; classes are strictly the nuts and bolts of how to design lower cost products. The design concepts are presented in a format engineers can easily apply while designing. Classes are very direct and to the point.

After attending class, engineers can and have immediately used these design concepts to quickly lower product cost. A few after class examples are:

One company’s engineers redesigned their mainline product in three months to reduce part cost by 35% and assembly time by 40% after attending class! Learn how to do the same from this example.

One company’s engineers took what they learned about how to eliminate fasteners and immediately started to overhaul existing products achieving hundreds of thousands of dollars in annual cost savings within the first year.

A capital equipment manufacturer adopted the weldment design concepts learned in class. They significantly lowered new and existing machine product cost, lowered new machine tooling costs by a million dollars and reduced new machine development time by a year.

David has helped redesign numerous products to reduce costs, overhead, time to market and improve quality. He is known for his out of the box thinking for ways to solve design and process problems and for his practical solutions.

His knowledge of how product design drives direct and indirect costs gives him the ability to show engineers how to lower cost in many dimensions. He understands both sides of the cost coin, design and process, and how to lower cost in both.

Many companies need classes on both, how to Design for and Apply LEAN Manufacturing to lower costs.

Process improvement classes to lower costs are:

How to Lower Machined Part Costs by 50%, Click Here

Designing the Assembly Process, Click Here

He has help client’s lower product and manufacturing costs wherever he found either opportunity in 300+ consulting engagements. His experience spans over forty years in a wide variety of industries, product types and manufacturing processes. He has done numerous product design reviews to determine a product’s manufacturability and to lower its costs. He has spoken at 21 International Conferences and presented hundreds of training sessions on the class material outlined. For more about his experience, Click Here

If you would like to receive updates on new classes email Dave@pdfm.info

Learn How to Lower Product Costs

Schedule onsite training tailored to your company’s needs

+1 (510) 928-0690 or email Dave@pdfm.info

*Details about time frame and training option for each class is on the Class page.

TESTIMONIALS

“Dave’s manufacturing experience gives him a unique perspective on minimizing part count and multiple functions of design, I have learned a lot of new concepts from him" “He understands manufacturing cost better than anyone with a wide diversity of experience. He is truly an out of the box thinker and brilliant at taking cost out of designs. I recommend him as the best person to explain how to design products for manufacturing." "His vast array of firsthand knowledge of products and processes… saved our company over $900K in annual cost savings in reducing product cost while reducing lead time to market. Listen to him, learn from him and grow wealthy with him!”

Greg King, Manager Mfg. Eng.

Cobham SATCOM

“He understands manufacturing cost better than anyone with a wide diversity of experience. He is truly an out of the box thinker and brilliant at taking cost out of designs. I recommend him as the best person to explain how to design products for manufacturing."

Mina Cox, Owner, COO

Specialty Products

“Dave’s manufacturing experience gives him a unique perspective on minimizing part count and multiple functions of design, I have learned a lot of new concepts from him"

Hai Tang, Senior Design Engineer

Western Valve

"Dave Waliszewski is an outstanding product development and manufacturing consultant who generates amazing results for his clients. He has developed unique concepts that are brilliant in their simplicity that will challenge some people who are stuck in “not invented here”

Jim Moar, Former President

DataCard

"David professionalism handling questions and tailoring the course to our specific needs... received numerous comments on the quality of class materials, presentation techniques and ability to relate to people... made this class one of the best courses I have even seen."

H. N. Bourdo, Training & Education Mgr.

Boeing Commercial Airplane Co.

On many occasions he has seen it was the product design and not the process that needed improving.

For example:

David was asked by Verhulst, NL to streamline the assembly process for a newly released product. After an hour looking at the assembly process David told the client it would be a waste of his time and their money to have him streamline this assembly process. The only way the process could be improved was by completely redesigning the product.

Client suggested they could take the product off shore. Dave’s response was, an ugly design is still ugly no matter where it is produced.

David worked with the design team four times over two months. The end result was a 49% cost reduction in parts and materials used. On the assembly side, 8 assemblers had struggling to assemble 50 per shift, now 2 assemblers are assembling 100 per shift.

Bottom line, the product stayed on shore.

Post Script:

Subsequently, Engineering started applying the design concepts learned to existing products. This has resulted in several hundreds of thousands of dollars in additional annual cost savings.

Product Design for LEAN

Manufacturing & Assembly:

Learn How to Lower the Cost of Parts, Weldments & Assembly

How to Design to Leverage Manufacturing Processes to Dramatically Lower Cost

Engineering Change & New Product Introduction:

Learn How to Process ECOs & Apply DFM at Same Time

Learn How to Develop Support Teams & Speed Products Development

How to Reduce Machined Part Cost by 50% Class:

Learn How to Apply LEAN Manufacturing to Lower the Cost of Machined Parts.