DESIGN FOR MANUFACTURING AND ASSEMBLY PREPARED BY- PRASHANT TRIPATHIvvvVYYYYVY What is DFMA? NW Principles of DFMA Introduction to assembly Dpetan ioe cen hy AU) erste teers nti 1a DFA Index BU inte. Index SA A A 20 NA A Bivisees uence DOUG IVT oraby VON one Estimating Manufacturing Costs DYNO Toa Wein emer D) VL feet Other example-Reticle assembly for a thermal gun DEFMA Software ayers NGWhat is DFMA? > Aset of guidelines developed to ensure that a product is designed so that it can be easily and efficiently manufactured and assembled with a minimum of effort, time, and cost. > Products designed using DFMA principles should have higher quality and reliability than others. > DFMA also ensures that the transition from the design phase to the production phase is as smooth and rapid as possible.What is DFMA? (conta) > Itis a concurrent engineering team approach PMU eR crete teeter ena Te BSN. WiniccteelrTim i Tey cette meoltes TUET ete > The cross-functional team work towards minimizing the number of components, manufacturing steps and operations while designing to proven manufacturing capabilities.Design Concept Design for Assembly (DFA) t Selection of materials and processes and early re Suggestions for simplification of product structure Production DFM cost estimates Suggestions for more ‘economic Bast dhelgereancapt materials and processes + Design for Manufacture (DFM) Detail design for minimum manufacturing costs PrototypePrinciples of DFMA SPO Un niycemesemee tie 2. Make Parts Multi-Functional 3. Design parts to be self-aligning and self-locating. 4. Use stack assemblies. 5. Ensure the ease of handling of parts from bulk. 6. Eliminate Interfaces. Pa ecrumetce ines euhelllccntoccct ha 8. Maximize part symmetry if possible or make parts obviously asymmetrical. 9. Use Standard Parts and Hardware 10. Simplify and Optimize the Manufacturing Process1. Minimize part count POUCA TRV MC oN MOM Merit ee en lie-e tha co) ete RCN MNT Tea CCE TS number of parts is reduced, product quality and reliability typically increase » A Simple Test to Determine if a Part Can Be Eliminated BANU (lat teperia mee Ce Coe NCR CONe)! fom) oe 1e Spe tve Paromita oeurer tits PANU Ii ia tertaaeesenr(e Mey Mel ta Coes stnent ler Jey SRNU Ua emer tae m seer tele er oroslor ee a > If the answer to these three questions is "NO", then the possibility of combining the part with other parts should be considered.2. Make Parts Multi-Functional > Multi-functional parts combine several functions into one part and reduce roeyun ye) esas3. Design parts to be self-aligning and self-locating. Peo etathtgr reunion c tae ett with no adjustment required. Pateetercun + This makes assembly easier and faster for the assembly workers. + Examples of self-locating features include projections, indentations, chamfers, molded keyways, etc.4. Use stack assemblies Fem One oe oot es Ch miei arae a he One way to do this is to design parts for stack assembly Gemeente ine somo ects Requires less reorientation of the components which RSceRMI RES haseelsce Not using gravity generally requires the use of additional tooling and fixturing.5. Ensure the ease of handling of parts from bulk > Parts should be designed with Prete Ei nFeae tae ave Pearson tet tangled/nested together when mixed together in a box or a bin. > Minimize the potential for eerommnta era lettered feoyecertitausslipperiness sharpness flexibility Ww eS6. Eliminate interfaces > Interfaces increase the cost of an assembly. » Each interface doubles the amount of information required and increases overall assembly time. > Eg : 2 sets of dimensions, 2 sets of tolerances, 2 SDL ccrue Cece CoreVeLLe cours —ins le) bya C2) oTelT assembly materials, ete. at7. Design parts that cannot be installed incorrectly. * Use physical obstructions to stop components Lone TLC CeBT MUR Va Ken eae) CamO eis ce ite Seite The name for this is “Poka-yoke”. Mistake-proofing8. Maximize part symmetry if possible or make part: obviously asymmetrical. Nineteen ee te enn * These irregularly-sized and spaced holes force Seca Dee cerita tem eNmratiey Frome INA Rem UTTTD TE Ccenroe toe ent ete ON Loe terrane UTE TaGt eters tn ene eta symmetry. achieve correct orientation during manual asse (CMSs ane b aceasta)9. Use Standard Parts and Hardware > Standardization requires increased communication between the design teams. > Reduces the number of tools required for assembly and lowers assembly cost. Pap Moe lom Cop Eon bccn tleat roe) my U Teer icelyor tena Votes nota mec ue meu OMULB NEL various resources such as the preferred parts lists, standard parts manuals, vendor fenedietsom ere man tecd anise10. Simplify and Optimize the Manufacturing Process > Simplification and optimization of the manufacturing process reduces recurring Celitroume Tema deli ieeCe noes > Using processes that are easily controllable. > Avoiding, where possible, processes that are difficult to control (i.e., welding, brazing, ete.). > Performing like operations simultaneously.11. Encourage modular assembly PV CEIzeme ence nit ese eae PMSSU Deiter reatnle hime) eacieCoiesLive Muar) coy }eele)(ertay identification easier by reducing the number of parts. Pm Ce ErmetSteserle hareU Cota} ) ib bteuseh elem artic d Tiny MeCa MEV cea ened Tire nm (eel ILA > By designing parts as separate, self-contained modules, disassembly time is reduced, fewer tools are required, and overall repair time is reduced.Introduction to assembly Pe Cento acorn yess > Designers can have a major influence on the cost and quality of an assembly. » The assembly task also involves... » Storing » Handling BO costttentit Sin feytititea Saat » Securing Pi ikslcee telDesign for Assembly (DFA) Sune omnne Morn ee temo mbar Nora Vem ete Tce @D) gO RERCOrn eT ng considered together as DFMA. Simplifies the product structure since the total number of parts in a product is a key Fintetrentose ie leeiter Ws[ tral HT ba Optimizes manual as well as automated assembliesWhich Parts are Essential? e Both the Boothroyd & Dewhurst, and Lucas methodologies use the idea of fundamental or essential parts. e All non-essential parts should be evaluated in case they can be designed out. » The Lucas methodology labels parts as “A’ (essential) and ‘B’ (target for designing out), * Boothroyd & Dewhurst use ‘1’ and ‘0’, but the result is similar.Does this part move relative to all parts which have already xg Is the movement essential for the capacity. wordpress. Must the part be separate to provide the required 2 been analysed? Bioauch te tuncueri? movement? Is this part of a different level itereai Mists parte material to all parts already analysed, with ‘which there was no relative. nh] material essential for the product to function?’ eparate to satisly the different material requirement? Is the part separate to allow for its. in-service adjustment or replacement? Is the adjustment ‘or replacement essential? Must the part be separate to enable the adjustment or replacement? yy Wy WF:DFA Index * An essential ingredient of the DFA method. «> DFA index is the assembly time for an “ideal” design divided by the total assembly time and expressed as a percentage. * The DFA index is a figure obtained by dividing the theoretical minimum assembly time by the total assembly time. The equation for calculating the DFA index Em: is, Where, bre TELE nee nTaeto Rey [iret Pe Com Tien Matt ere con ohatin#Throwback... PeMUaetcconpesc none tyros Do ULEn Nath cere econ Perma oreneor ne) Pe MESON CRSM ES Mos scod san Met tcn YS Com Croaeen cnet SMMC ve terete ny acceso niente eletencrat tense Riera > U.S. designers preferred to use the new computers rather than perform hand calculations to Purana Soret as Coker ont Wy eros Mertrntesed UlENventn DDyeatene CG cnt RSE COm eon R oa TED o.oo bun ioeu Rca tree tens Pee ae steno Mier ink ar Cr OS Ry een Orcom enna any reported that DFA software had helped them save billions of dollars on their Taurus line of PE eens,Introduction to DFM > DFM is the method of design for ease of manufacturing of the collection of parts. > Minimizes complexity of manufacturing operations. > Like DFA ,DFM also shortens the product development cycle time. Pam tKeenosetcemi alm ccele tae core vmpeeeli encom > It seeks to utilize standards to reduce the costs.Major DFM objectives Estimate the mfg. costs Reduce the costs of components ae ee Mee eesott le) ay Reduce the costs of supporting production Consider the impact of DFM decisions on other factors.Estimating manufacturing costs. © “ Reduce costs of Reduce costs of Reduce costs of components assembly Supporting Production 4% ‘Consider DFM impact onother factors 4% Recompute Manufacturing Costs N ¥ Y Good Enough? ] > [__Accepted Design _]Why use DFMA? aa ages dialogue between designers and the manufacturing engineers. This means th ee Osean nonee tensor eeecny Be eooe eNom ensiette suns Bae enetcen soir nIi5 7 PM enter COVE UM Nn eed VE So RSireed cere eee nro eT rireaD) SM nt Ca yet soc nurture lass eterU NT COMMm TL CONUS cece TCC Om ORR the time for a product to go from conception to the consumer (total time-to market) is reduced.Reasons for not implementing DFMA > No Time > Not Invented Here > The Ugly Baby Syndrome > Low Volume > DFMA Leads to Products That Are More Difficult to Service > I Refuse to Use DFMA325° attached to screw drive connecting wires + motor driven assembly inside controlied gapResults of Design for Assembly (DFA) Analysis for the Motor Drive Assembly Proposed Dé ‘Theoretical Assembly No. part count time (s) Base 1 1 3.5 Bushing 2 o 12.3 Motor subassembly 1 1 O58 Motor screw 2 © 21.0 Sensor subassembly 1 1 8.5 Set screw 1 oO 10.6 Standoft 2 o 16.0 End plate 1 1 84 End plate screw 2 o 16.6 Plastic bushing 1 o 3.5 ‘Thread leads $.0 Reorient — — 4.5 ‘Cover 1 o 94 Cover screw 4 0 31.2 ‘Totals 19 4 160.0 Design ctticsency = “2S a 7:5%Results of Design for Assembly (DFA) Analysis for the Motor Drive Assembly Redesig Theoretical Assembly No. part count time (s) Base 1 1 3.5 Motor subassembly 1 1 4.5 Motor screw 2 0 12.0 Sensor subassembly 1 1 8.5 Set screw 1 0 8.5 Thread leads _— _— 5.0 Plastic cover 1 1 4.0 Totals 6 4 46.0 4x3 Design efficiency = a = 26%> The second step in an analysis is Design for Manufacture (DFM). > By using DFM, carly cost estimates for the parts are obtained for both the original design and the néw design in order to make trade-off decisions. > During this process the best materials and processes to be used for the various parts are considered.Comparison of Parts Cost for the Motor Drive Assembly Proposed Design and Redesigr (purchased motor and sensor subassemblies not included) (a) Proposed design (b) Redesign Item Cost (S) Item Cost (5 Base (aluminum) 12.91 Base (nylon) 13.43 Bushing (2) 2.40" Motor screw (2) 0.20 Motor screw (2) 0.20" Set screw 0.10 Set screw 0.10" Plastic cover 6.71 ‘Standoff (2) 5.19 (includes tooling) End plate 5.89 End plate screw (2) 0.20" ‘Total 20.44 Plastic bushing 0.10" Cover 8.05 Tooling cost for plastic cover, $6307 Cover screw (4) 0.40" Total 35.44> This is an indication that itis important not only to know the total estimated manufacturing cost of an item but, more importantly, to know the cost of providing the various features: part manufacturing costs.> . ==> ; 4. Ss s&s wing > Source: Boothroyd, Dewhurst and Knight (1994)Other example Original design of a reticle assembly for a thermal gunsight in a US tank, made by Texas Instruments, Ine Berge Metron envi ste Bey Sle tesma ee htnae nea eects ean teticle: simpler to assemble, and less to g0 wrong! Onc ae S‘Assembly time (h) Number of different parts Total number of parts Total number of operations Metal fabrication time (h) Weight (1b) 2.15, 24 47 58 12.63 0.48 3.65 0.26 84.7% 66.7% 74.5% 77.6% TAA% 45.8%DFMA Software > Boothroyd Dewhurst, Inc. has developed a software package to implement DFMA techniques. > Calculates the costs involved for different materials and manufacturing processes as we as identify areas where the number of parts can be reduced. > Easily considers the impact of using alternative materials and manufacturing processes. > Documented significant reductions- Pee EC eo Dosa sTed olbnot capacify.wordpress.com > Product Design for Manufacture and/Assembly: Second Edition, Revised and Expanded, Geoffrey Boothroyd, Peter Dewhurst, and Winston Knight Panos > www.dima.comTHANK YOU!!