Quick Takeaways
- Small design decisions can significantly increase fabrication costs and lead times
- Overly tight tolerances and complex geometries are among the most common manufacturability challenges
- Early collaboration with fabrication partners helps reduce rework and project delays
- Simpler designs frequently deliver the same real-world performance at a lower total cost
- Designing with manufacturing in mind improves project efficiency, reliability, and overall value
Why Design for Manufacturability Matters
In the power generation industry, component performance and reliability are non-negotiable. Engineers are tasked with creating parts that can withstand demanding operating conditions while meeting stringent industry requirements. However, many designs are developed with ideal operating scenarios in mind rather than the realities of fabrication.
The result is often a component that is technically sound but unnecessarily expensive, time-consuming, or difficult to manufacture.
Design for Manufacturability (DFM) is the practice of creating parts that satisfy performance requirements while remaining practical and efficient to produce. When manufacturing considerations are addressed early in the design process, organizations can reduce costs, accelerate production schedules, and avoid unforeseen fabrication challenges.
For power generation projects where downtime, maintenance outages, and equipment upgrades carry significant financial implications, these benefits can have a substantial impact on project success.
Common Design Mistakes Engineers Make
1. Over-Specifying Tolerances
One of the most common and costly design mistakes is applying extremely tight tolerances across an entire component.
While tighter tolerances may seem like a safer engineering choice, they often require:
- Additional machining operations
- Specialized equipment
- Increased inspection requirements
- Slower production times
In many cases, certain dimensions have little impact on overall component performance and do not require such precision.
What to Do Instead
Apply tolerances based on functional requirements rather than blanket specifications. Identify critical dimensions where precision is essential and allow reasonable tolerances elsewhere. This approach can significantly reduce fabrication costs without compromising performance.
2. Creating Complex Geometries That Add Little Value
Advanced CAD tools make it easy to create highly intricate designs. However, what looks impressive on a computer screen may present major fabrication challenges on the shop floor.
Features that frequently increase manufacturing complexity include:
- Intricate contours and curved profiles
- Deep or hard-to-access pockets
- Difficult-to-reach weld locations
- Unnecessary transitions and detail features
These elements can require additional welding, custom fixtures, specialized tooling, or multiple machining setups.
What to Do Instead
Whenever possible, simplify component geometry. Straight cuts, standardized profiles, and accessible weld joints generally lead to shorter production times, lower fabrication costs, and fewer quality concerns.
3. Ignoring Material Availability
Material selection is another area where manufacturability is often overlooked.
Specifying uncommon alloys, custom thicknesses, or non-standard material formats can create sourcing challenges that delay production and increase project costs. Even a well-designed component can stall if required materials are difficult to obtain.
What to Do Instead
Use standard material grades, thicknesses, and dimensions whenever application requirements allow. In power generation work, mild steel is the most commonly used material for its durability and cost-effectiveness, while stainless steel and aluminum are used in other applications. Commonly available materials can typically be sourced faster, processed more efficiently, and purchased at a lower cost.
4. Designing Without Considering Welding Requirements
Welded assemblies are common throughout power generation systems, from support structures and ductwork to pressure-retaining and process-related components.
Poor joint design often creates manufacturing complications such as:
- Limited weld accessibility
- Inconsistent joint thicknesses
- Distortion during fabrication
- Excessive fit-up and rework
- Reduced weld quality
When welders cannot easily access joints or maintain consistent weld conditions, production efficiency and overall quality can suffer.
What to Do Instead
Design weld joints that are accessible, repeatable, and consistent. Consider weld placement, joint preparation, and fit-up requirements during the design phase. A fabrication partner can often provide valuable guidance on how to improve weldability without affecting performance.
5. Waiting Too Long to Involve Fabricators
Perhaps the biggest missed opportunity in many projects is failing to engage fabrication experts until after the design is finalized.
Fabricators bring practical production knowledge that complements engineering expertise. Their input can help identify:
- Cost-saving design modifications
- Faster manufacturing approaches
- Material alternatives
- Potential quality concerns
- Production bottlenecks before they occur
A simple adjustment early in design can prevent costly revisions later in production.
What to Do Instead
Engage fabrication partners early in the development process. Design reviews conducted before drawings are released can uncover opportunities to improve manufacturability while preserving performance requirements.
The Real Impact on Power Generation Projects
When manufacturability is overlooked, the consequences extend far beyond the shop floor.
Common outcomes include:
- Longer lead times
- Increased fabrication costs
- Greater risk of rework
- Project schedule delays
- Installation challenges
- Increased maintenance outage durations
For power generation facilities, delays can translate directly into reduced output, extended downtime, and significant financial losses. Improving manufacturability helps ensure components move efficiently from design to production, keeping projects on schedule and within budget.
Best Practices for Engineers
To improve manufacturability and project outcomes, engineers should:
- Collaborate with fabrication teams before designs are finalized
- Use standard materials whenever practical
- Favor simple, efficient geometries
- Specify tolerances based on actual functional requirements
- Evaluate how each feature will be manufactured
- Consider welding accessibility and assembly requirements early
- Seek feedback from manufacturing experts during design reviews
These practices can help reduce production risks while maintaining the performance and reliability demands of power generation applications.
Final Thought
The most successful power generation components are not only technically correct. They are also practical to manufacture.
By incorporating Design for Manufacturability principles early in the engineering process, organizations can reduce costs, shorten lead times, minimize rework, and improve project outcomes. When engineers and fabricators work together from the start, the result is a smoother path from concept to installation and a stronger return on investment for every project.
At Jones Metal, we work closely with engineers, OEMs, and power generation facilities to identify manufacturing efficiencies early and deliver high-quality fabricated components that meet demanding performance requirements without unnecessary production complexity. Jones Metal also manufactures its own products, including ENVALT pad mount transformer enclosures for single-phase and three-phase transformers, each backed by a leakproof guarantee.