A custom machine design project can bring together many elements, including mechanical design, electrical control systems, software, machined and fabricated parts, motion devices, and pneumatics. With so many components that must work together, decisions made early in the design process can have a major impact on cost, schedule, manufacturability, and final machine performance.
A well-planned custom machine design review provides an opportunity to identify problems before they reach the shop floor. I also brings engineering, manufacturing, quality, supply chain, and the customer together to confirm that the design is ready to move forward.
What Is a Custom Machine Design Review?
A custom machine design review is a structured evaluation of a machine design at specific stages of development. Depending on the project, reviews may occur at the concept stage, during detailed engineering, and again before the machine design is released for manufacturing.
The purpose is not simply to confirm that the CAD model looks correct. A good design review asks practical questions hat help find issues during the design review that may only require a simple engineering change:
- Does the design meet the customer’s functional requirements?
- Can the machine be manufactured and assembled as assigned?
- Are tolerances appropriate and achievable?
- Can technicians access components for assembly and maintenance?
- Are safety requirements adequately addressed?
- Are critical components available within the project schedule?
- Can the completed machine be properly inspected and tested?
Finding an issue during a design review may require a relatively simple engineering change. Finding the same issue after parts have been machined or equipment has been assembled can be more expensive.
Design Reviews Improve Manufacturability
A machine can work perfectly in a 3D CAD model and still be difficult to manufacture. Experienced machinists, fabricators, assemblers, and manufacturing engineers can identify issues that may be easy to overlook in initial design.
Reviews may uncover:
- Difficult machining features
- Poor weld accessibility
- Unnecessarily tight tolerances
- Assembly or tooling limitations
- Difficult cable, tubing, or pneumatic routing
- Components that cannot be easily serviced after installation
Addressing these issues early can simplify manufacturing, reduce rework, and improve the overall reliability or the equipment.
Cross-Functional Reviews Catch Different Problems
Custom machinery designs rarely succeed though mechanical engineering alone. Quality may identify an inspection requirement that needs better access. Supply chain may discover that a specified component has a long lead time or is approaching obsolescence. Manufacturing may recommend a different fabrication method. Assembly technicians may recognize that a component cannot be installed in the planned sequence.
Often, the improvements identified are relatively small. Moving a component, changing a tolerance, adding an access panel, or selecting a more readily available part may prevent a much larger problem later.
Design Reviews Help Control Project Risk
Every custom machine project has technical and schedule risks. A design review provides an opportunity to identify the areas that deserve additional attention before the machine is built.
These may include:
- Critical dimensions and tolerance stack-ups
- Structural integrity
- Operator and equipment safety
- Maintenance and service access
- Component availability
- Inspection and acceptance criteria
For particularly complex equipment, the review may also identify areas where additional analysis, testing, or prototyping would be worthwhile.
Documentation Should Be Part of the Review
A design review should verify that the documentation needed to manufacture the machine is complete and consistent. This can include:
- 3D CAD models and drawings
- Bills of material (BOMs)
- Electrical schematics
- Pneumatic and fluid diagrams
- Component specifications
- Software and controls requirements
- Inspection and test requirements
Revision control is especially important. Manufacturing a component from an obsolete drawing can quickly erase the time saved by rushing to a design release.
Design Reviews for Design & Build and Build-to-Print Projects
Design reviews are valuable for both design & build and build-to-print custom machinery, although their scope my differ.
For a design & build project, reviews help move the project from initial requirements through detailed engineering and final design release. The machine builder can address performance, manufacturability, safety, serviceability, and cost as the design develops.
For build-to-print machinery, design ownership typically remains with the customer. However, a manufacturing review before production can identify missing information, conflicting drawings, tolerance concerns, supply chain issues, or assembly challenges before they affect the build.
How Keller Technologies Approaches Custom Machine Design Reviews
At Keller Technology, custom design reviews are integrated into the execution of complex custom machinery projects, Depending on the project, the review may involve engineering, manufacturing, quality, supply chain, project management, and customer personnel.
Rather than making the process more complicated than necessary, the focus is on practical questions: Is the design manufacturable? Are customer requirements clear? Are quality and inspection requirements defined? Are there technical, documentation, or supply chain concerns that need to be resolved before release?
The objective is to ask the right questions while there is still time to make changes to the machine design efficiently.
Better Decisions Before Manufacturing Begins
The best time to correct a custom machine design is before material is ordered and manufacturing begins.
A disciplined design review helps align engineering intent manufacturing capability, and customer expectations. It can reduce rework, protect the project schedule, improve equipment quality, and make final assembly and testing smoother.
For complex custom machinery, design reviews are one of the most effective ways to identify and reduce risk before it becomes expensive.
Ready to Get Started?
If you’re ready to begin the custom machine design process, let’s talk. Keller can help you identify problems, save time and money, and improve efficiency.