Design for manufacturing excellence (DFMX) begins at the freshman level

A freshman engineering course taught by experienced faculty members can attract students to the challenges and demands of career as modern manufacturing engineers. The article illustrates this general approach with the specific details for one successful, inexpensive, challenging but “fun” project. Students work within a multi-disciplinary team to design, produce and test a production aircraft that meets statistical quality control performance goals set by the customer. The team optimizes the manufacturing floor to minimize variable and fixed costs using the basic skills provided in the introductory lectures and laboratories. The project includes an executive summary, a preliminary report, a performance trial of the aircraft, a final report, detailed drawings and a capstone team presentation. Teamwork is demanded of all participants at all levels.