• Project Scope

Achieving cost reduction

Reducing number of LEDs

Meets customer needs (picture quality PQ & Brightness)

Simple Metal beck cover design

• Process followed

Standard design process

- Concept design

Gathering all needs and requirements of the design

- Detailed design

3D/2D design

Design for manufacturing DFM

Design for assembly DFA

Simulation analysis

Prototyping

- Pilot run

Tooling manufacturing.

Verification tests

- Pre-production

- Mass production

• Methodologies Adopted

Cost breakdown analysis of components

Benchmarking against competitor designs

Root cause analysis of existing overdesign

• Trials or Ideations Done

Conducted trials with reduced LED counts.

Testing picture quality and brightness

• Outcome

- Achieving the main goals of the design

Reducing number of LEDs 2 instead of 8

Achieved cost saving

- Keeping customer needs

Normal PQ

Normal brightness

• Challenges Faced

- Meeting Functional Requirements

Will the part perform its intended function reliably?

Can it handle expected loads or stresses?

Does it operate safely under normal and extreme conditions?

- Dimensional Accuracy & Tolerances

Precision is critical, especially for assemblies

There needs to be a balance between design accuracy and manufacturability (DFM)

- Design for Manufacturability (DFM)

Is the part easy and cost-effective to manufacture?

Does it require complex processes, custom tooling, or molds?

- Cost

Is the part too expensive to produce?

- Potential Production Defects

Warping, voids, surface defects, tolerance issues in injection molding, casting, etc

- Ensuring picture quality was not compromised after reducing the number of LEDs