After everyone on the team gave their thumbs-up, the data for the parts were electronically transferred directly into computer-aided manufacturing systems at the various suppliers. The NCR designers were so confident everything would work as intended that they didn’t bother making a mock-up.
DFM can be a powerful weapon against foreign competition. Several years ago, IBM used Boothroyd Dewhurst’s software to analyze dot-matrix printers it was sourcing from Japan-and found it could do substantially better. Its Pro printer had 65 percent fewer parts and slashed assembly time b¥ 90 percent. “Almost anything made in Japan,” insists Professor Boot hroyd, “can be improved upon with DFM-often impressively.”