Boston Engineering DFX Focus Areas

DFC focuses on meeting cost targets through design optimization.

Our DFC capabilities include:

• Estimating manufacturing costs early through detailed production analysis
• Tracking cost breakdowns of materials, labor, tooling, etc.
• Targeting high cost drivers for reduction or elimination
• Utilizing common parts and processes to maximize volumes
• Simplifying components for easier production
• Evaluating alternative materials, processes, sourcing options

We design products with testing in mind to verify performance and reduce cost of testing.

DFT tactics include:

• Incorporating test points and interfaces for electrical/electronic modules
• Designing mechanical assemblies for easy fixturing and access during testing
• Defining critical test parameters and tolerances upfront
• Utilizing modeling and simulation to enable virtual testing when possible
• Specifying standardized tests using industry best practices
• Designing products for automated testing when applicable

To meet reliability goals, we utilize techniques like:

• Selecting components with sufficient quality and ratings for the application
• Performing derating, FMEA, thermal analysis, etc. to ensure robust design
• Adding redundancy into the design where necessary
• Specifying materials, surface finishes, etc. suitable for the operating environment
• Running HALT/HASS testing to uncover failure modes and mechanisms
• Reviewing legacy field performance data to inform reliability improvements

We design products for service and maintenance throughout their lifecycle.

DFS techniques include:

• Designing modules/components for easy removal/replacement
• Incorporating self-diagnostics capabilities and error logging/reporting
• Specifying quick-access panels and fasteners for common repair tasks
• Defining preventative maintenance schedules to maximize uptime
• Minimizing service parts inventory through commonality and modularity
• Creating detailed service documentation and training for field technicians

DFU focuses on optimizing the user experience.

Our DFU expertise includes:

• User research to understand needs, workflows, and environments
• Prototyping interfaces for user feedback
• Applying human factors standards appropriate for the product
• Iterating designs based on usability testing
• Validating designs through final user testing

DFMo involves creating interchangeable components that enable product flexibility.

Our DFMo capabilities include:

• Identifying common subsystems, modules and interfaces
• Defining modular architectures balancing flexibility and cost
• Utilizing common components and production processes
• Designing interfaces enabling field upgrades and enhancements