ABSTRACT
DFM included not only designing parts for ease of manufacture but also to minimize the need for machining which generates waste, as shown by the key performance indicators (KPIs) for waste of material and energy. Ford minimized this waste by stamping or forging several pieces to near-final shape and then welding them together rather than casting a large piece and then machining large quantities of metal from it. Any process that produces huge piles of metal shavings (and used cutting fluid) should be questioned immediately as a source of material and energy waste.
