3.

1 DESIGN EFFICIENCY ANALYSIS ON EXISTING DESIGN

Design efficiency analysis is to define the percentage of efficiency during
assembly process. To calculate the efficiency should to follow the steps one by
one. For the first step is identify function of part refer to sub topic 3.2
(Description and function of part) and then proceed to step 2 until step 4.

STEP 2: Identify Alpha (α) and Beta (β) for each part
To identify alpha and beta of part need to consider the rotation of each during
assembly process. The alpha and beta is the important value of angle because
the total of angle symmetric use to evaluate the manual handling time, manual
insertion time and proceed until find the design of efficiency.
Alpha Beta
No Part Part Name Quantity
(α) (β)

1 Adjustable 1 360° 360°

thermostat

Iron Elements
2 (heating coil) 1 360° 360°
with soleplate

3 Base 1 360° 360°

4 Selector switch 1 360° 360°

5 Wire tighter 1 180° 360°

 Adjuster-
6 thermostat 1 360° 360°
connector

7 Indicator light 1 360° 360°

display

8 Shell / Body 1 360° 360°

9 Handle 1 360° 360°

10 Stand-off 5 0° 180°

Pan head 5 0° 360°

11
Screw 1

Pan head
12 Screw 2 (with 2 0° 360°
washer)

Pan head
13 Screw 3 (with 2 0° 360°
washer)

14 Raised Screw 5 0° 360°

Table 8: Alpha and Beta of each part.

STEP 3: Identify manual handling time.

To identify manual handling need to refer to manual handling time table to get
the code and finally get the estimated time by knowing the symmetric rotation
angle, and the size of each part.

Manual Manual
Part Part
Part Name Handling Handling
No. Quantity
Code Time (s)
1 Adjustable thermostat 1 30 1.95

2 Iron Elements (heating 1 30 1.95

coil) with soleplate
3 Base 1 35 2.73
4 Selector switch 1 35 2.73
5 Wire tighter 1 80 4.10

6 Adjuster-thermostat 1 30 1.95
connector
7 Indicator light display 1 30 1.95
8 Shell / Body 1 30 1.95
9 Handle 1 35 2.73
10 Stand-off 5 00 1.13
11 Pan head Screw 1 5 50 4.00

12 Pan head Screw 2 (with 2 50 4.00

washer)
13 Pan head Screw 3 (with 2 50 4.00
washer)
14 Raised Screw 5 50 4.00
Total 39.17
Table 9: Manual handling time.
STEP 4: Identify manual insertion time.
To identify manual insertion time need to refer to manual insertion time table to
get the code and finally get the estimated time by knowing how to assembly and
way to connected parts.

Manual Manual
Part Part
Part Name Handling Handling
No. Quantity
Code Time (s)
1 Adjustable thermostat 1 06 5.5

2 Iron Elements (heating 1 92 5.0

coil) with soleplate
3 Base 1 28 10.5
4 Selector switch 1 30 2.0
5 Wire tighter 1 26 9.5

6 Adjuster-thermostat 1 30 2.0
connector
7 Indicator light display 1 30 2.0
8 Shell / Body 1 38 6.0
9 Handle 1 38 6.0
10 Stand-off 5 30 2.0
11 Pan head Screw 1 5 92 5.0

12 Pan head Screw 2 (with 2 92 5.0

washer)
13 Pan head Screw 3 (with 2 92 5.0
washer)
14 Raised Screw 5 92 5.0
Total 70.5
Table 10: Manual insertion time
STEP 5: Assembly cost
To identify assembly cost need to find assembly time by adding manual
insertion time and manual handling time then calculate using formula giving
cost per hour is RM30.
Assembly cost
Theoretical Assembly (CM)
Part Part Part [Assembly
part count time (TM)
No. Name Quantity 𝟑𝟎
(NM) (s) time x 𝟑𝟔𝟎𝟎𝒔 ]
(RM)
1 Adjustable
1 1 7.45 0.062
thermostat
2 Iron
Elements
(heating 1 1 6.95 0.058
coil) with
soleplate
3 Base 1 1 13.23 0.110
4 Selector
1 1 4.73 0.039
switch
5 Wire
1 0 13.6 0.113
tighter
6 Adjuster-
thermostat 1 1 3.95 0.033
connector
7 Indicator
light 1 0 3.95 0.033
display
8 Shell /
1 1 7.95 0.066
Body
9 Handle 1 1 8.73 0.072
10 Stand-off 5 0 3.13 0.026
11 Pan head 5 3 9.00 0.075
Screw 1
Pan head
12 Screw 2 2 2 9.00 0.075
(with
washer)
Pan head
13 Screw 3 2 2 9.00 0.075
(with
washer)
14 Raised 5 3 9.00 0.075
Screw
Total 28 17 109.67 0.912
Table 11: Assembly cost
STEP 6: Calculation of design efficiency analysis
The last step to find design efficiency is calculated by using formula given.

𝑁𝑀
𝐷𝐸𝑆𝐼𝐺𝑁 𝐸𝐹𝐹𝐼𝐶𝐼𝐸𝑁𝐶𝑌 = × 3𝑠
𝑇𝑀

NM = theoretical part count

TM = assembly time (s)
3s = 1.5 seconds for handling time and 1.5 seconds for insertion time

𝟏𝟕
𝑫𝑬 = × 𝟑 = 𝟎. 𝟒𝟔
𝟏𝟎𝟗. 𝟔𝟕

Percentage design efficiency = 𝐃𝐞𝐬𝐢𝐠𝐧 𝐞𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 × 𝟏𝟎𝟎%

= 𝟎. 𝟒𝟔 × 𝟏𝟎𝟎

= 𝟒𝟔%