DFM Design for Assembly

Prepared By A.S.Deshmukh

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DFM Design for Assembly A process for improving product design for easy and low-cost assembly, focusing on functionality and on assemblability concurrently."

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Benefits of Design for Assembly

Reduce cost of assembly Improve quality and reliability Reduce part inventory Reduce production equipment

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Assembly Methods
1. 2. 3. Manual Assembly Fixed automatic Assembly Flexible automatic Assembly

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Manual Assembly
Parts are transferred to workbenches where workers manually assemble the product or components of a product. Hand tools are generally used to aid the workers. Most flexible and adaptable of assembly methods, there is usually an upper limit to the production volume, and costs (including benefits, cases of workers compensation due to injury, overhead for maintaining a clean, healthy environment, etc.) are higher.

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Design Guidelines for Manual Assembly

1. Eliminate the need for workers to make decisions or adjustments. 2. Ensure accessibility and visibility. 3. Eliminate the need for assembly tools and gauges. (i.e. prefer self-locating parts). 4. Reduce the number of different parts - use "standard" parts. 5. Minimize the number of parts. 6. Avoid or minimize part orientation during assembly (i.e. prefer symmetrical parts). Prefer easily handled parts.

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Fixed automatic Assembly

Fixed or hard automation is characterized by custom-built machine that assembles one and only one specific product. This type of machinery requires a large capital investment. As production volume increases, the fraction of the capital investment compared to the total manufacturing cost decreases.

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Design Guidelines for Fixed automatic Assembly Reduce the number of different components by considering does the part move relative to other parts? Use self-aligning and self-locating features, avoid screws/bolts up to maximum extend. Use the largest and most rigid part as the assembly base and fixture. Assembly should be performed in a layered, bottom-up manner. Use standard components and materials. Avoid tangling or nesting parts. Avoid parts that require orientation. Use parts that can be feed automatically.
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Flexible Automatic Assembly

This is Soft automation assembly system which incorporates the use of Robotic assembly systems. This can take the form of a single Robot, or a multi-station Robotic assembly cell with all activities simultaneously controlled and coordinated by a PLC or computer. This type of assembly method can also have large capital costs. Compared to Humans, Robots are extremely inflexible and stupid. However, they can be programmed to do one thing over and over again with high speed and accuracy compared to humans. Design the part so that it is compatible with the robot's end effectors. Design the part so that it can be feed in the proper orientation.

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Relative costs of different assembly methods by type and production volume

Figure 2: Production ranges for each type of assembly method

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How much do engineering changes cost after the design has been launched?
10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Design Test Tool Build Prod

Cost

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Basic DFA Principles of Good Design 1. Design for minimum number of parts
Is there a way that reduces the number of required parts? Are all components essential or can their functions be achieved by modifying an existing component? Can components be combined into one and manufactured as an integral multifunctional component? Less parts implies less purchases, inventory, handling, processing time, development time, equipment, engineering time, assembly difficulty, service inspection, testing, etc.

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DFA Examples

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2. Minimize number of fasteners and their components

Use snap fits where possible. Use press fits where disassembly is not required. Consider molded hinges, straps, or hook-under. Rationalize fasteners - types, lengths etc. Use one piece fasteners with lead in pilots. Design geometry for automatic alignment.

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3. Design the product for assembly from one direction

Where possible assemblies should be designed so that a base piece is established, and remaining parts assembled from one, ideally vertical (Z) direction. It is difficult to feed components in from the side.

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4. Avoid the need to turn the assembly over

If previously placed components have not been fastened, they may move out of position. Datum and location points change, and complicate the assembly process, which leads to jamming and assembly failure.

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5. Standardize on Components, Materials, and Fasteners

Components can be difficult to differentiate, particularly small similar shaped ones. It is relatively common for feeders to become jammed because wrong parts have been fed in by operators. Considerable savings in storage, inventory, ordering etc.

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6. Provide location surfaces that are closely related to datum surfaces

This ensures a known location tolerance for the automatic placing of components. Care should be taken to avoid tolerance build-up.

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7. Consider ease of disassembly for maintenance, service, repair, and recycling

Integral snap fits, press fits, and retaining clips (circlips) allow compact designs, but if care is not taken, result in impossible disassembly. Disassembly is frequently necessary due to incorrect assembly, the need to service/repair.

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8. Adopt a modular design philosophy for the product group

Allows model variations to be accomplished at a sub-system level. Subassembly volumes increase, total parts decrease. Modular sub-assemblies may be built and tested by specialist teams (higher quality).

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9. Avoid the need for assembly adjustments

Eliminating adjustments will usually reduce assembly time considerably; and reduce service / maintenance Equipment going out of adjustment is one of the biggest causes of customer dissatisfaction. Spring loading can be used effectively to avoid assembly adjustment and to eliminate adjustment for wear.

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10. Minimize assembly steps and extra operations

Each assembly step or operation must be resourced. Mistakes in assembly are one of the greatest cause of product malfunction and customer returns. The fewer the steps the fewer the opportunities for error. Extra operations such as applying grease, sealants, turning part over etc. add to time and reduce assembly efficiency.

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DFA Example-1

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DFA Example 2

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DFA Example-2

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DFA Example-2

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DFA Example-2

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Example-3

Assy Before DFA Process

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Example-3

Assy After DFA Preocess

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MOTOR DRIVE ASSY

Proposed Design Before DFA

Final Design After DFA

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 End of session-1

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DFA: The Lucas Method

The Lucas DFA method was developed in the early 1980's by the Lucas Corp. in the U.K. Lucas method is based on a "point scale" which gives a relative measure of assembly difficulty. The method is based on three separate and sequential analyses. These are best described as part of the assembly sequence flowchart (ASF):

1. Specification 2. Design 3. Functional analysis (this is the first Lucas analysis) Possibly loop back to step 2 if the analysis yields problems 4. Feeding analysis (this is the second Lucas analysis) 5. Fitting analysis (this is the third Lucas analysis) 6. Assessment Possibly return to step 2 if the analyses identify problems
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Functional Analysis
In this analysis, the components of the product are reviewed only for their function. The components are divided into two groups. 1. Group A:Parts that belong to this Group are those which are deemed to be essential to the product's function. 2. Group B:Parts that belong to this Group are those which are not essential to the product's function. Group B functions include fastening, locating, etc. The functional efficiency of the design cal be calculated as: Ed = A/(A+B) x 100% where A= Number of essential components B= Number of non-essential components. Note that the design efficiency is used to pre-screen a design alternative before more time is spent on it. This analysis is intended to reduce the part count in the product. Typically, a design efficiency of 60% is targeted for initial designs.
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Feeding Analysis
In the feeding analysis, the problems associated with the handling of the part are scored using an appropriate table. For each part, the individual feeding index is scored. Generally, the target index for a part is 1.5. If the index is greater than 1.5, the part should be considered for redesign. Overall, all of the product's components should meet a "feeding ratio" defined as: Feeding Ratio = (Total Feeding Index) / (Number of Essential Components) where the total feeding index is the sum of all the indices of all the parts. The number of essential components is the value A from the functional analysis. An ideal feeding ratio is generally taken to be 2.5.

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Fitting Analysis The fitting analysis is calculated similarly to the feeding analysis. Again, a fitting index of 1.5 is a goal value for each assembly and overall fitting ration of 2.5 is desired. Fitting Ratio = (Total Fitting Index) / (Number of Essential Components)

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REFERENCES:

DFM/DFA Tool Kit (Appendix A) Tucson SFC Program Management Procedure (TU-PGM-18-001) Seat Engineering DFA (DENG-04-025) Weight Reporting Procedure (DENG-04-019)

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