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(DfA)
Engr. Wan Sharuzi Hj Wan Harun
Industrial Engineering, FKM
Introduction
• Design is a complex iterative creative
process that begins with the
recognition of a need of desire and
terminates with a product or process
that uses available resources, energy
and technology to fulfil the original
need within some set of defined
constraints.
• Assembly is a process of joining
components into a complex product.
Introduction (cont….)
• Design for “X”
– manufacturing
– safety and reliability prevention
– quality (six sigma)
– environment
– serviceability
– testability
– functionality
– assembly
– others ……..
Introduction (cont….)
• Time-based competition,
– Ability to quickly develop,
– Produce and distribute new products,
– Processes.
• Progressive development,
• Diversification to meet customer
needs.
Introduction (cont….)
• Rapid changes in markets and
technology tend to bring shorter
product life cycles.
• Developing products quickly to
reduce lead times correlated with:
– Cost,
– Quality
Introduction (cont….)
• Product development includes all the
activities from market needs interpretation
and technical possibilities to finished
production designs.
– Drawings, specifications,
– Tools, fixtures and production programs,
– Prototype production,
– Test activities.
Approaches to Product
Development
• Today’s products are becoming
increasingly complex.
• In many companies, design and
manufacturing exist as separate
groups. “Over the wall” approach to
design.
Design for Assembly
(DfA)
• Design for Assembly (DfA) is an
approach to reduce the cost and time of
assembly by simplifying the product
and process through such means as:
– Reducing the number of parts.
– Combining two or more parts into one.
– Reducing or eliminating adjustments.
– Simplifying assembly operations.
– Designing for parts handling.
– Selecting fasteners for ease of assembly.
– Minimizing parts tangling.
Design for Assembly
(cont….)
Design a product for easy & economical
production.
Incorporate product design early in the design
phase.
Improves quality and reduces costs.
Shortens time to design and manufacture.
Design for Assembly
(cont….)
(a) The original design
Assembly using
common fasteners
Design for Assembly
(cont….)
(a) The original design (b) Revised design
– User-friendly
Design for Assembly
(cont….)
• Four basic approaches for
implementing DfA have been
identified:
– Design principles and rules,
– Quantitative evaluation procedures,
– Expert/Knowledge-based approach,
– Computer-Aided DFA methods.
Design for Assembly
(cont….)
• Design principles and rules
– Based on human oriented knowledge.
– Collectively design data and convert
assembly knowledge to design
principles, rules and guidelines.
Design for Assembly
(cont….)
• Quantitative evaluation procedures
– Based on evaluation procedure.
– Determine the assembly process
operation by operation.
– Quantitative measure is calculated.
Design for Assembly
(cont….)
• Expert/Knowledge-based approach
– Based on knowledge-based technology –
a knowledge base, inference,
communication and knowledge
acquisition.
Design for Assembly
(cont….)
• Computer-Aided DFA methods
– DFA systems are integrated with CAD
systems.
– Key role is the representation of
technical objects and procedures for
extraction and processing of
assemblability attributes from 3D CAD
models.
Aspects of
Design for Assembly
• DfA is applicable to:
– Products consisting of 20 - 200 parts.
– Mainly for mechanical parts (not electronics).
• Implementation techniques
– Consider the part for elimination.
– Use common parts.
DfA Guidelines (cont….)
– Eliminate features or functions not of
value.
– Eliminate fasteners.
– Design multifunctional parts.
• Outcomes
– Improves quality, reduces opportunities
for defects.
– Shortens product design time.
DfA Guidelines (cont….)
– Reduces the total material cost.
– Simplifies vendor selection.
– Reduces labor content.
– Reduces assembly time.
– Simplifies the assembly process, factory
layout.
– Reduces need for unique tools.
– Reduces warehouse/stockroom space.
Design for Assembly
Methods
• Several systems being used in industry:
– The DfA method exploited by Boothroyd
Dewhurst Inc., USA.
– The Hitachi Assemblability Evaluation
Method (AEM) by Hitachi Ltd, Japan.
– The Lucas Design for Assembly
Methodology by Lucas-Hull, UK.
Where DfA fits in
the design process?
• The design process is an iterative,
complex, decision-making engineering
activity that leads to detailed drawings
by which manufacturing can
economically produce a quantity of
identical products that can be sold.
• The design process usually starts with
the identification of a need, proceeds
through a sequence of activities to seek
an optimal solution to the problem, and
ends with a detailed description of the
product.
Where DfA fits in the
design process? (cont…)
• Design process involves 3 main phases:
i. Feasibility study,
ii. Preliminary design,
iii. Detail design.
• During the feasibility study, plausible
solutions are explored, and rough checks
are made on performance and product
costs.
• Performance specifications for the most
promising ideas are quantified during the
preliminary phase.
• The detail design results in the piece-part
and assembly drawing.
Where DfA fits in the
design process? (cont…)
• Design for assembly (DfA) – considered
at all stages of the design process.
• Concepts – analyzed against cost and
performance. A systematic analysis of
product assemblability – performed.
• If cost and performance analyses
require a concept to be redefined, the
efficiency of assembly – analyzed before
final approval.
Boothroyd-Dewhurst
DfMA Methodology
Analyse for
Assembly
OR
Analyse for
OR Special-purpose
assembly transfer
machines
Analyse for Manual
Assembly
– Handling
– Insertion and fastening
Boothroyd-Dewhurst
DfA Method (Cont.)
• Assembly efficiency for manual assembly
3 x NM
EM =
TM
α = 1800 α = 3600 α = ?
Effect of Part Symmetry
on Handling Time (Cont.)
β -symmetry: rotational symmetry about its axis of
insertion.
β =0 0 β = 1800 β =?
Effect of Part Symmetry
on Handling Time (Cont.)
Thickness: The length of the shortest side of the
smallest rectangular prism which encloses the part.
Size: The length of the longest side of the smallest
rectangular prism that can enclose the part.
Thickness
Size
Thickness
= radius
Exception
General Rule when cylindrical and
Diameter < Length
Effect of Part Symmetry
on Handling Time (Cont.)
• Several different approaches have been
employed to determine relationships
between the amount of rotation
required to orient a part and the time
required to perform that rotation.