Perancangan Produk

08
Modul ke:

Design for Manufacture (DFM) and Assembly

(DFA).

Fakultas
Haris Wahyudi, ST. M.Sc
Teknik

Program Studi
Teknik Mesin
Topic Outlines
A. Introduction
B. Objectives of DFM
C. DFM Methods
D. Some Rules for DFM
E. DFM + DFA = DFMA
F. DFA Guidelines

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A. Introduction
• Manufacturing comprises a large number of distinct
processes which can effect cost, part quality and
productivity.
• Design for Manufacture (DFM) is the first step in
which a team approach is taken to develop the
product.
• DFM is an umbrella which covers a variety of tools
and techniques to accomplish a manufacturability
product.
• DFM is concerned with understanding the
interactions and optimizing the system

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

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Introduction
• What is DFM?
– Design for Manufacturing (DFM) is a development practice
emphasizing manufacturing issues throughout the product
development process.
– Successful DFM results in lower production cost without sacrificing
product quality.
• Why DFM?
 Lower development cost
 Shorter development time
 Faster manufacturing start of build
 Lower assembly and test costs
 Higher quality
• So, Design For Manufacture(DFM) means the design for ease
of manufacture of the collection of parts that will form the
product after assembly

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Example: GM Intake Manifold

Aluminum
$38.51

Thermoplastic
$21.93
66% lighter

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B. Objectives of DFM
• The objective of DFM is to identify product
concepts that are easy to manufacture
• Focus on component design for ease of
manufacture and assembly
• Integrate manufacturing to ensure the best
match of needs and requirements.

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C. DFM Methods
• Design for Manufacturing (DFM) aims in
improving the manufacturability or producibility
of a single product by reducing manufacturing
costs.
Proposed/
Best Design Reduce
the Costs of
Components
No
Estimate Reduce Consider Impact Re-Compute Good
Manufacturing the Costs of of DFM Decisions Manufacturing Enough?
Costs Assembly on Other Factors Costs
Yes
Reduce
the Costs of
Acceptable
Supporting
Design
Production

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C. DFM Methods
• Estimate the manufacturing costs.
• Reduce costs
– Costs of components
– Costs of assembly
– Costs of supporting production.
• Consider the impact of DFM decisions on other
factors.

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Estimate the Manufacturing Costs
Equipment Information Tooling

Raw Materials

Labor
Manufacturing System Finished Goods
Purchased
Components

Energy Supplies Services Waste

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Manufacturing Costs Defined
• Sum of all the expenditures for the inputs of the
system:
– purchased components
– Energy
– raw materials, etc.)
• Cost for disposal of the wastes produced by the
system

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 Elements of the Manufacturing Cost of a Product

Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material

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D. Some Rules for DFM
1. Minimize the total number of parts/simplify
the design
2. Use standard components
3. Develop a modular design
4. Use liberal tolerances
5. Design parts for ease of fabrication
6. Design parts for ease of assembly
7. Work with manufacturing personnel

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1. Minimize total parts
• Less time expended in drawings, part numbers,
production records, material handling, service
parts, catalogs, parts for quality control, assembly
processes, etc.
• A part can be eliminated if:
– there’s no relative motion with all the other parts in the
assembly,
– independent service, repair and maintenance.
– made of a different materials
• But should not occur to the point where
eliminations adds cost by making part unnecessarily
complex.
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1. Minimize total parts – cont’d
• Combine parts (integral design)
– replace fabricated sub – assembly
with a single precision castings or
moulding
– make use of integral hinges and
springs in plastics
• Make parts multi-functional
– F1 engine is also a structural member
– a spring can also be a structural
component
– a conductor can also be structural.
– Design in assembly aids such as
aligning features

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2. Use Standard Components & Materials
• Stock items are always less expensive than
custom made items.
– use same size nuts, bolts, screws etc where ever
possible.
• They can be obtained with little or no lead time
• Easier to repair or replace
• Standard components are more reliable
• Can be ordered in any quantity at any time
• Transfers burden to supplier

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Example of standard components

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3. Develop modular design
• A module is a self contained component with a
standard interface to other components.
• Product customization via different combination of
modules.
• Ease of service, repair and upgrade.
– Defective module can be easily replaced
• Simpler assembly
• Can add cost and complexity from extra
connections and fittings
• Many examples in the computer and electronics
industries.
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• A computer is actually one of the best examples
of modular design - typical modules are:
– power supply units
– Processors
– Mainboards
– graphics cards
– hard drives
– optical drives, etc.

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4. Use liberal tolerances
• Close tolerances increase
cost
– Extra machining
– Operations
– High tooling cost
– Scrap/rework
– Costly precision
equipment.
• Same for surface
finishes.
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5. Design for ease of fabrication
• Use the least costly material & process
appropriate for the application
– free machining brass vs conventional brass
– use processes appropriate for production
run – e.g.: die cast vs sand cast.
• Use near-net shape processes and avoid
secondary processing
– deburring, painting, heat treatment etc, can
be as expensive as primary manufacturing

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6. Design for assembly
• A lot more about this later…..
–minimize use of fastener
–avoid flexible components
–minimize assembly directions
–minimize handling
–avoid parts that can be tangled.

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7. Work with manufacturing personnel
• Most producible designs occur when design and
manufacturing engineers work closely together
from outset (start, beginning)
• All aspects of the design are considered from
the outset
• 70-80% of the cost of the component is
determined in the design stage.

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E. DFM + DFA = DFMA
• DFMA is the integration of the separate but
interrelated design issues of assembly and
manufacturing processes.
• DFMA procedure is applied as early as possible
in the design process and used within a
concurrent engineering teamwork environment.

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DFMA Objectives
• DFMA Goal:
–Maximize the use of manufacturing
processes and minimize the number of
components in an assembly or product.
–The result is simpler and more reliable
products that are less expensive to
manufacture and assemble

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DFM vs. DFA
DFM (Manufacture)
• Systematic procedure to
maximise the use of
manufacturing processes in the
design of components
• DFM will help you to:
– analyze and compare the costs
of different materials and
manufacturing methods, in the
design phase
DFA (Assembly)
• Systematic procedure to
maximise the use of
components in the design of a
product
• DFA will help you:
– estimate the difficulty of
assembly,
– eliminate unnecessary parts
and assembly tooling,
– design products that are less
costly to manufacture.
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DFMA

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DFMA (previous flow chart)
• The DFA analysis is conducted first, leading to
simplification of the product structure

• Then, early cost estimates for the parts are obtained for
both the original design and the new design in order to
make trade-off decision

• During this stage, the best materials and processes to be

used are considered

• Once the materials and processes have been finally

selected, a more thorough analysis for the DFM can be
carried out for the detail design of the parts.

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F. DFA Guidelines
1. Minimize the total number of parts
– A part is not required by the design is a part that
does not need to be assembled

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DFA Guidelines
2. Avoid separate fastener
– The use of screws in assembly is expensive.
– Snap fits should be used whenever possible

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Type of snap fits

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DFA Guidelines
3. Minimize assembly direction
– All parts should be designed so that they can be
assembled from one direction
– The need to rotate in assembly requires extra time
and motion and may require additional transfer
station and fixtures

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DFA Guidelines
4. Minimize the amount of material and Minimize
number of different materials
– Less energy required to produce/move
– Less landfill, esp. true for packaging!
– Use thermoplastics rather than thermosets
– Do you need paint, esp. on plastics?
– Avoid welding dissimilar metals
– Can cause conflict with initial manufacturing cost
objectives

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DFA Guidelines
5. Minimize compliance in assembly
• Designed-in compliance features:
– Part symmetry
– Avoid tangling
– Fillet and chamfer etc.

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Terima Kasih
Haris Wahyudi, ST. M.Sc