I started out in the electronics engineering field, and moved into the software side of electronics design automation business shortly after that. Back in the early 1990's a lot of effort was being put into Design for Manufacturing. This was in the recognition that very small decisions made early by an isolated engineer, could have massive consequences down the road impacting costs. There were a few leaders and advocates in the field, mainly from HP and IBM at the time.

One incident recalled by Happy Holder, a HP engineer at that time was the reduction in cost of the HP Laserjet III printers. By altering the size of the main printed circuit board size by a few inches one way, they were able to double the production yield of that assembly, halving the raw material cost of the PCB. Happy Holden and IBM's Tucker Garrison at the time came up with a few simple methods for evaluating designs and allocating a report card. The most complex part of the process was getting the right people in the room to agree on the right criteria to measure, and to weight those measurements in the right way.

Manufacturing optimization comes down to improving production yield (reducing waste) and speeding up the process (reducing touch time); These principles are well known to all those proponents of Lean Manufacturing and Theory of Constraints. This book is a good start - Agile Management for Software Engineering: Applying the Theory of Constraints for Business Results (The Coad Series).

Is software yield (throughput) equivalent to DFM for Electronics "Speeding up the process"? The aforementioned books clearly describes the process of improving throughput by reducing the waste and understanding the current blocking issues. But I cannot find a process that brings focus of the cost of decisions back to the earliest possible decision point, when it is relatively simple to move many directions.

It seems obvious there is room for innovation here. Provide a framework (what DFM calls report cards) that developers and architects can use to assess possible solutions and designs for a requirement. I plan over the next few weeks to explain how the Electronics DFM process worked, and suggest a few techniques that might improve our up-front decision making process.

Troy.