Boothroyd & Dewhurst’s DFA Analysis

• B&D offer eight rules or guidelines which are important

during design for manual assembly (listed in decreasing
order of importance):
1. Reduce part count and part types
2. Strive to eliminate adjustments
3. Design parts to be self-aligning and self-locating
4. Ensure adequate access and unrestricted vision
5. Ensure the ease of handling parts from bulk
6. Minimize the need for re-orientations during assembly
7. Design parts that cannot be installed incorrectly
8. Maximize part symmetry if possible or make parts obviously
asymmetrical 1
 Boothroyd & Dewhurst’s DFA Analysis (cont.)
Step 1: Obtain information about the product or assembly
from drawings, prototypes, or an existing product
Step 2: Take the product or assembly apart and assign an
identification number to each item as it is removed
Step 3: Begin to reassemble the product beginning with
the highest identification number and add the remaining
parts one-by-one
– Complete one row of the DFA worksheet for each part
– Never assume that parts are grasped one in each
hand and then assembled together before placing
them in a partially-completed assembly
• Step 4: Complete DFA worksheet, computing total
manual assembly time, cost, and design efficiency 2
 0
Name of Part

9
8
7
6
5
4
3
2
1
1

Part ID #

20
19
18
17
16
15
14
13
12
11
10
# of times the
2

operation is carried out

consecutively
two-digit manual
3

handling code
manual handling time
4

per part
two-digit manual
5

insertion code
manual insertion time
6

per part
operation time, sec,
7

TM
(2) x [(4) + (6)]
operation cost, cents,
8

CM
0.4 x (7)
estimation of
9

theoretical minimum #
DFA Worksheet

NM
of parts, 0 or 1
Manual
Manual

Insertion
Handling

Obtained
Obtained

from B&D
from B&D

Worksheet
Worksheet

Design Efficiency
EM = (3 x NM)/TM
3
Estimating Theoretical Minimum Number of Parts
First Part;
Add a part Theoretical #
of parts = 1

Is there a need for significant Yes

movement between parts?
No

Is there a need for interfacing Yes

parts to be isolated?
No
Would assembly or disassembly of the Yes
product be prevented by combining two parts?
No
Keep the two
Combine the two parts
parts separate

Add zero to the Add one to the

minimum theoretical minimum theoretical
number of parts number of parts

Add next part

4
Assumptions for BDI DFMA

• Parts are provided in bulk and randomly

oriented in a bin.
• Parts are handled and inserted one at a time.
• Products weigh a few grams to a few tens of
kilograms and are electro-mechanical in nature.
• Assembly sequence is optimized for one
operator.

5
 Assembly Time Estimate by
Boothroyd/Dewhurst DFMA

Estimate assembly time:

– Time to assemble a part:
»Time to handle a part
»Time to insert a part
– Time to assemble all parts, one at a time

6
BDI DFMA: Assembly Time
• Time to handle a part:
– Pick a part, orient & get ready to insert it
– 1.13 ~10 seconds depending on:
»Symmetry; Primary(α-) & secondary(β-)
»Size: Thickness, dimension, weight, …
»Handling ease: Tool, flexible, tangling, ...

7
8
 BDI DFMA: Part Symmetry

• Primary (α-) symmetry: Rotational symmetry

perpendicular to the axis of insertion

α = 180o

α = 360o

9
 BDI DFMA: Part Symmetry

• Secondary (β-) symmetry: Rotational symmetry

about the axis of insertion

β = 0o β = 360o
10
 DFA Worksheet Part Orientation
• α asymmetry: rotational symmetry
•about an axis perpendicular to the
•axis of insertion

α = 3600
α = 1800 α = ?
=

11
 DFA Worksheet
Part Orientation
β symmetry: rotational
symmetry about its axis of insertion

β = 00 β =?
β = 180 0

12
BDI DFMA: Part Symmetry

13
14
BDI DFMA: Part Size

15
BDI DFMA: Assembly Time
• Time to insert a part:
– Time to insert and secure a part
– 1.5 ~ 12 seconds depending on:
» Ease of access: Visual & hand access
» Ease of positioning: Hold-down,
alignment, insertion force, ..
» Securing requirement: Screw, snap,
bending, soldering, ….
• Time to assemble all parts, one at a time

16
BDI DFMA: Assembly Time
• Time to insert a part

• Two-digit insertion codes for piston:

__ __

17
BDI DFMA: Assembly Time
• Time to insert a part

• Two-digit insertion codes for washer:

__ __
18
BDI DFMA: Assembly Time
• Handling Time

19
BDI DFMA: Assembly Time
• Insertion Time

20
 BDI DFMA: Assembly Time

• Total Assembly Time

Qty Handling Handling Insertion Insertion Assembly

Part # Part Name
(n) Code Time Code Time Time (n Parts)
1
2
3
4
5
6
Total Assembly Time

21
Pneumatic Pump Exercise with
Boothroyd/Dewhurst DFMA

22
BDI DFMA: Pneumatic Pump
• Assembly Sequence:
6. Two screws
5. One cover
4. One spring
3. One piston stop
2. One piston
1. One main body
• Tool:
– A screw driver
23
 BDI DFMA: Pneumatic
Pump
• Assembly Time:

Qty Handling Handling Insertion Insertion Assembly

Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1
2 Piston 1
3 Piston Stop 1
4 Spring 1
5 Cover 1
6 Screws 2

24
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1
3 Piston Stop 1
4 Spring 1
5 Cover 1
6 Screws 2
Total Assembly Time

25
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1
4 Spring 1
5 Cover 1
6 Screws 2
Total Assembly Time

26
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1 10 1.50 00 1.50 3.00
4 Spring 1
5 Cover 1
6 Screws 2
Total Assembly Time

27
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1 10 1.50 00 1.50 3.00
4 Spring 1 05 1.84 00 1.50 3.34
5 Cover 1
6 Screws 2
Total Assembly Time

28
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1 10 1.50 00 1.50 3.00
4 Spring 1 05 1.84 00 1.50 3.34
5 Cover 1 12 2.36 08 6.50 8.86
6 Screws 2
Total Assembly Time

29
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1 10 1.50 00 1.50 3.00
4 Spring 1 05 1.84 00 1.50 3.34
5 Cover 1 12 2.36 08 6.50 8.86
6 Screws 2 11 1.80 39 8.00 16.60
Total Assembly Time 40.75 Seconds

30
 Part Reduction Method by
Boothroyd/Dewhurst DFMA

31
BDI DFMA: Part Reduction
• Estimate assembly time:
• Identify critical parts & candidates for
elimination/combination. Let’s assume a
product consists of a number of parts:
– Are they all critical part?
– What if a part is missing or broken?
– What if two parts are replaced by a larger
or different part
• Determine design efficiency

32
 BDI DFMA: Part Reduction
When ready to assemble a part, should this part:
• Move relative to all already assembled parts?
• Be made of different material from all already
assembled parts?
• Be a separate part from all already assembled
parts for assembly and disassembly?

If any answer is a “yes”, this part is a critical part

and may not be eliminated or combined!

33
BDI DFMA: Why Reduce Parts?

A non-existing part never:

• Causes a quality problem
• Adds the cost
• Creates an inventory problem
• Requires design changes
• Creates a shortage problem
• Has a lead time

34
BDI DFMA: Pneumatic Pump
• Assembly Sequence:
6. Two screws
5. One cover
4. One spring
3. One piston stop
2. One piston
1. One main body

35
 BDI DFMA: Pneumatic Pump
• Part Reduction:
With Relative Different Service & Critical
Part # Part Name Qty
Respect to Motion Material Assembly Part
1 Main Block 1
2 Piston 1 Main Block
3 Piston Stop 1 Main Block
Piston
4 Spring 1 Main Block
Piston
Piston Stop
5 Cover 1 Main Block
Piston
Piston Stop
Spring
6 Screws 2 Main Block
Piston
Piston Stop
Spring
36
 BDI DFMA: Pneumatic Pump
• Part Reduction:
With Relative Different Service & Critical
Part # Part Name Qty
Respect to Motion Material Assembly Part
1 Main Block 1 -- Yes
2 Piston 1 Main Block
3 Piston Stop 1 Main Block
Piston
4 Spring 1 Main Block
Piston
Piston Stop
5 Cover 1 Main Block
Piston
Piston Stop
Spring
6 Screws 2 -- No

37
 BDI DFMA: Pneumatic Pump
• Part Reduction:
With Relative Different Service & Critical
Part # Part Name Qty
Respect to Motion Material Assembly Part
1 Main Block 1 Yes
2 Piston 1 Main Block Yes Yes
3 Piston Stop 1 Main Block
Piston
4 Spring 1 Main Block
Piston
Piston Stop
5 Cover 1 Main Block
Piston
Piston Stop
Spring
6 Screws 2 -- No

38
 BDI DFMA: Pneumatic Pump
• Part Reduction:
With Relative Different Service & Critical
Part # Part Name Qty
Respect to Motion Material Assembly Part
1 Main Block 1 Yes
2 Piston 1 Main Block Yes Yes
3 Piston Stop 1 Main Block No No Yes Yes
Piston Yes Yes
4 Spring 1 Main Block
Piston
Piston Stop
5 Cover 1 Main Block
Piston
Piston Stop
Spring
6 Screws 2 -- No

39
 BDI DFMA: Pneumatic Pump
• Part Reduction:
Candidate
With Relative Different Service & for
Part # Part Name Qty
Respect to Motion Material Assembly Eliminatio
n
1 Main Block 1 Yes
2 Piston 1 Main Block Yes Yes
3 Piston Stop 1 Main Block No No Yes Yes
Piston Yes Yes
4 Spring 1 Main Block Yes Yes
Piston Yes Yes
Piston Stop Yes Yes
5 Cover 1 Main Block
Piston
Piston Stop
Spring
6 Screws 2 -- •Yes
No
40
 BDI DFMA: Pneumatic Pump
• Part Reduction:
Candidate
With Relative Different Service & for
Part # Part Name Qty
Respect to Motion Material Assembly Eliminatio
n
1 Main Block 1 Yes
2 Piston 1 Main Block Yes Yes
3 Piston Stop 1 Main Block No No Yes Yes
Piston Yes Yes
4 Spring 1 Main Block Yes Yes
Piston Yes Yes
Piston Stop Yes Yes
5 Cover 1 Main Block No No Yes Yes
Piston Yes Yes
Piston Stop No No No No
Spring Yes Yes
6 Screws 2 -- •Yes
No
41
DFA of Pneumatic Pump
• According to the piston stop, the cover is a
candidate for elimination or combination:
– Can the cover be eliminated?
– Can the cover be combined? If so with
what?
• Fasteners are automatic candidates of
elimination:
– How can the fasteners be eliminated?

42
Part Reduction Is the Key
for Design Improvement
• Eliminating one part reduces at least 3
seconds.
• In addition a non-existing part is the best
since it never:
– Requires purchasing and warehouse
– Needs inspection
– Causes a quality problem
– Needs design changes and drawing
– Be in shortage
43
DFA of Pneumatic Pump
• According to the piston stop, the cover is a
candidate for elimination or combination:
– Can the cover be eliminated? No!
– Can the cover be combined? Yes!
Combine with piston!
• Fasteners are automatic candidates of
elimination:
– How can the fasteners be eliminated?
Yes! Press-fit the cover!

44
New Design of Pneumatic Pump

45
BDI DFMA: Design Efficiency
• The pneumatic pump:
– Has 7 parts & needs 40.75 seconds to assemble
– Has 4 critical parts & 3 non-critical parts
• If the product is designed perfectly:
– Pump would consists of only four parts
– Each part would take 3 seconds to assemble
– Total assembly time would be 12 seconds
• Design efficiency from assembly view points is:
– Design Efficiency = 12/40.75 = 29%
46
 BDI DFMA: Pneumatic
Pump
• Assembly Time:
Qty Handling Handling Insertion Insertion Assembly
Part # Part Name
(n) Code Time Code Time Time (n Parts)
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 10 4.00 5.50
3 Piston Stop 1 10 1.50 00 1.50 3.00
4 Spring 1 05 1.84 00 1.50 3.34
5 Cover 1 12 2.36 08 6.50 8.86
6 Screws 2 11 1.80 39 8.00 16.60
Total Assembly Time 40.75 Seconds

– What should we do to reduce handling time of

the cover and insertion times of the cover and
screws?
47
 BDI DFMA Assembly
Time
• 1.13 ~10 seconds to handle a part depending on:
– Symmetry; Primary(α-) & secondary(β-)
– Size: Thickness, dimension, weight, …
– Handling ease: Tool, flexible, tangling, …
• To reduce part handling time:
– More part symmetry: α- & β-symmetry
– Right part size : Thickness, dimension, …
– No flexible, tangling parts

48
To Reduce Handling Time

• Increase symmetry • Closed-end springs

by introducing do not tangle
redundancy: α −
symmetry from 360o
to 180o
49
BDI DFMA Assembly Time
• 1.5 ~ 12 seconds to insert a part depending on:
– Visual & hand access
– Hold-down, alignment, insertion force,
– Securing: Screw, snap, bending, soldering, ..
• To reduce part insertion time:
– Easy visual & hand access
– No hold-down, easy alignment, low/no
insertion force, ..
– Easy/No securing requirement: Snaps instead of
screw, bending, soldering, ….
50
To Reduce Insertion Time

• The washer seat • The long shaft makes

eliminates needs of piston alignment easy
holding

51
 New Design of Pneumatic
Pump
• Piston & piston stop are combined
• Cover is press-fitted

52
 New Design of Pneumatic
Pump
• BDI DFMA Assembly Time Analysis:
Handling Handling Insertion Insertion Total Assy
Part # Part Name Qty
Code Time Code Time Time
1 Main Block 1
2 Piston 1
3 Spring 1
4 Cover 1

53
 New Design of Pneumatic
Pump
• BDI DFMA Assembly Time Analysis:
Handling Handling Insertion Insertion Total Assy
Part # Part Name Qty
Code Time Code Time Time
1 Main Block 1 30 1.95 00 1.50 3.45
2 Piston 1 10 1.50 00 1.50 3.00
3 Spring 1 05 1.84 00 1.50 3.34
4 Cover 1 10 1.50 30 2.00 3.50
Total Assembly Time 13.29 Seconds

• Design comparison:
Old Design New Design % Change
Number of Parts 7 Parts 4 Parts 43% Reduction
Assembly Time 40.75 Seconds 13.29 Seconds 67% Reduction

54
 Design Guidelines for
Assembly
How to design a product for ease of assembly?
• Reduce the number of part
• Design each part for ease of handling
• Design each part for ease of insertion
• Examine trade-offs, other cost and other X’s

55
 Design Guidelines for
Assembly
• Reduce the number of part:
– Eliminate unnecessary parts
– Combine parts
– Reduce the different kinds of parts
– Reduce/eliminate fasteners

56
 Design Guidelines for
Assembly
• Design each part for ease of handling:
– Increase part symmetry but avoid near
symmetric parts
– Avoid tangling, nesting and sticky parts
– Reduce/eliminate fasteners
– Avoid custom-designed parts & use standard
parts
– Reduce part variability. If not possible, make
difference pronounced

57
 Design Guidelines for
Assembly
• Design each part for ease of insertion:
– Design for top-down layered assembly
– Enhance self-locating & alignment capability
– Provide in-process verification process
– Design the base part for transportation &
orientation & the last part to lock the assembly
– Avoid turnover & processing during assembly
– Design for one-hand assembly
– Design fixtures together with products

58
 Design Guidelines for
Assembly
• Examine trade-offs, other cost and other X’s:
• To hold a wash or provide a washer seat?
• Several standard parts or a single custom part?
• Different material?
• Different joining method?
• What about:
– Service & repair
– Packing and shipping
– Recycle ...
Assembly is only one of many cost factors!
59