Background

In the early 1970s, University of Massachusetts Professor Geoffrey Boothroyd and his colleagues embarked on pioneering research that would lay the foundation for the DFMA^® (Design for Manufacture and Assembly) software. Initially, their goal was to equip designers with a method to quantify product designs for ease of automatic assembly. Over time, this approach broadened to encompass manual assembly, enabling manufacturing engineers to justify automation proposals. This methodology was grounded in two fundamental principles:

1. Reduce the number of assembly operations by minimizing the number of parts.
2. Simplify the assembly operations to make them easier to perform.

These principles were a significant departure from the prevailing “producibility guidelines” of the era, which directed designers to focus on simplifying individual parts to make them easier and cheaper to manufacture. Dr. Boothroyd’s groundbreaking research revealed that this practice often resulted in substantially higher overall product costs compared to using fewer, multi-functional parts.

DFMA^® Software

The publication of this research sparked considerable commercial interest. In 1980, Dr. Peter Dewhurst joined Dr. Boothroyd to develop a software package called “Design for Automatic and Manual Assembly” (DFA) for the Apple II Plus. The success of this project attracted the attention of major corporations like IBM and Digital Equipment, leading to the development of a PC version and the incorporation of Boothroyd Dewhurst Inc. (BDI) in 1983. Prominent companies such as Ford and General Motors estimated savings in the billions of dollars thanks to DFA.

As DFA software gained traction, the need for precise knowledge of the cost savings it offered became apparent. In 1985, Drs. Boothroyd and Dewhurst conducted additional research that resulted in the creation of a “Design for Manufacture” (DFM) module. This module enabled early and accurate should-cost estimates of various design proposals. Together, DFA and DFM formed what is now known as DFMA^®. The immense benefits provided by DFMA^® software led President George H. W. Bush to award the founders of BDI the National Medal of Technology in 1991.

Pioneering the Next Generation of Efficiency

For over 40 years, Boothroyd Dewhurst Inc. (BDI) has continuously enhanced the DFMA^® software tool, adapting to the evolving manufacturing and technology landscape. BDI's deep industry knowledge ensures DFMA^® remains a vital solution for contemporary manufacturing challenges, providing robust and intuitive tools for design and cost analysis, facilitating quicker and more accurate decision-making.

Leading manufacturers worldwide rely on DFMA^® to maintain their competitive edge. The software's ability to deliver cost efficiency and product quality makes it indispensable in modern manufacturing. Advanced cost simulation technology further enhances DFMA^®'s capability to address today's manufacturing complexities.

Under the leadership of President Nicholas Dewhurst and Executive Vice President Keith Gilligan, BDI is committed to driving innovation and maintaining its position at the forefront of manufacturing efficiency, helping companies achieve unprecedented levels of performance and profitability.

BDI on LinkedIn

President George Bush awards the founders of Boothroyd Dewhurst, Inc., the National Medal of Technology "for their concept, development and commercialization of Design for Manufacture and Assembly (DFMA), which has dramatically reduced costs, improved product quality, and enhanced the competitiveness of major U.S. manufacturers." For more information about the Medal of Technology, please click here.

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