NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue

Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

Course Code and Title: Concurrent Engineering EIE 3222

Lecturer: I. MAPINDU
Cell: +263777912241
Email: [email protected]

GENERAL INSTRUCTIONS

1. Strictly no copying of work whether from classmate, previous assignments or any other
work.
2. Do not copy and paste work from the internet, journals or any other sources. Paraphrase
in your own words and using the Harvard Referencing style, properly acknowledge the
work.
3. Be as precise and concise as possible, apply the gathered knowledge to the specific
cases given, do not generalize.
4. Individual assignment to be submitted to the google classroom.
5. Group assignment to be submitted to the google classroom by only one person per
group.
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

Assignment 1: INDIVIDUAL ASSIGNMENT (Due 09/05/2023)

1 a) Following the DFMA steps can result in a design that is both cost effective for the
chosen assembly method and, at the same time, is in compliance with most DFMA
principles. Outline the DFMA steps and explain how these steps can result in a design
that is both cost effective for the chosen assembly method and is in compliance with
most DFMA principles. [14]

b) Write brief notes of a DFX of your choice making use of appropriate illustrations and
examples. [6]

c) Explain, with the aid of an illustration, the relative costs of different assembly
methods by type and production volume. [6]

2a) As a consultant Industrial engineering for Ground-force Engineering

Consultancy, you are required to come up with a competitive strategy for a client All-
things-camping (Pvt) Ltd that is into the manufacturing of outdoor equipment such
as caravans and other camping accessories and services. According to market
research done by the marketing department, there is a stiff competition in the market
and your client holds only 1% market share. Two factors have been established to be
the leading causes of this low market share: high cost of production which leads to
higher prices and lack of innovation and differentiation in the product and service
offering.

i. Using your knowledge of concurrent engineering concepts and applications,

you are required to develop a manufacturing strategy that will result in the
lowering of the manufacturing costs. You are required to give as much
details as possible including relevant examples of products that fall under
the category offered by the client [37].
ii. Develop a Blue Ocean Strategy that will enhance the innovation and
differentiation in the product and service offering of the client. In your
strategy, outline each step that has to be taken in order to develop and
implement it. Give relevant examples in your strategy. [37]
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

Assignment 2: Group Assignment (due 16/05/2023)

1) A. The management of Sorvene (Pvt.) Ltd. is experiencing quality challenges

in determining the optimal parameters that will result optimal micro-hardness
values HV in the laser cladded coating. The parameters in Table Q1a are to be
optimised.

Preheating %WC Energy Density

No 30 50
Yes 50 100

i. Determine the Taguchi experimental design orthogonal array for the

process. Use the conditions provided in the table above to fill in the array.
[2]

ii. Conducting three trials for each experiment, the data in Table Q1b was collected

EXPERIMENT No. Trial HV Trial HV Trial HV

1 1000 1100 1050
2 980 990 1000
3 1144 1236 1200
4 966 996 1006
5 1458 1563 1654
6 1856 1756 1654
7 1658 1568 1436
8 1789 1700 1650
9 1562 1548 1598

Apply Taguchi methods to determine the following:

(i) Factor averages. [3]

(ii) The S/N ratios. [8]
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

(iii) Factorial effects for the S/N ratios. [6]

(iv) Optimum condition. [1]

2a) The Lucas DFA method is one of the three major assembly evaluation method
(AEM) used. Using an appropriate diagram illustrate the Lucas Assembly-sequence
flowchart diagram.[5]

b) Use the Lucas DFA method on Figure Q2 to determine the:

i. Design Efficiency, [3]

ii. Feeding Ratio, [6]

iii. Fitting Ratio. [6]

Figure Q2

3) A Product is made from 50 parts and is to be manufactured in ten different styles

obtained by having one alternative for each of ten of the parts in the assembly. Ten
major design changes will probably take place during the first three years. Expected
annual production 210 000 units whilst 70 000 are produced per shift. As a matter of
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

company policy the amount that can be spent on an item of automation equipment
that will do the work of one operator on one shift is $50 000. The annual cost of one
(1) assembly operator is estimated to be $25 000. Using the chart Figure Q3 provided,
determine the best assembly method that can be used [20].

Figure Q3

KEY
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

NA – number of parts in the completed assembly.

ND – number of parts whose design is changed during the first three (3) years.

NP – number of different products to be assembled using the same basic assembly

system.

NT – Total number of parts available for building product styles.

QE – Capital expenditure allowance to replace one operator on one shift.

RI – Investment Factor: RI = SH x QE/WA

SH – Number of shifts.

VS – Annual production volume per shift.

WA – Annual cost of one assembly operator.

4) Classic Ride (Pvt.) Ltd. manufactures gear pumps. Use the Boothroyd-Dewhurst
method and the appropriate Manual Handling Estimated Times, Manual Insertion
Estimated Times and Manual Assembly Worksheet Tables, in Appendix Q5, determine
the Design Efficiency of the new design of a gear pump, shown in Figure Q4 [20]
 NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

Figure Q4

5) Assembly costs account for 40-60% of the total manufacturing cost of a product.
Hence reduction in assembly cost consequently, reduces the manufacturing cost.
Evaluate the product in Figure Q5 for ease of assembly using:

i. Lucas Method. [10]

ii. Boothroyd Dewhurst Method. [10]

NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering

Figure Q5
NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering
NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering
NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering
NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
P. O. Box AC 939, Ascot, Bulawayo, Zimbabwe Cnr. Gwanda Road/Cecil Avenue
Telephones: 263-292-282842/288413/39/58 or 263-292-286742
Fax: 263-292-289057
Department of Industrial and Manufacturing Engineering