2_design For Manufacture And Assembly (dfma)
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Design for Manufacture and Assembly (DFMA) BMF 4723 Engr. Wan Sharuzi Hj Wan Harun [email protected] 0197799152
Introduction • Is a combination between DFM & DFA DFM
Design for Manufacture Manufacturing of individual component parts of a product or assembly
DFA
Design for Assembly Addition or joining of parts to form a complete product
DFM? • The design for ease of manufacture of the collection of parts that will form the product after assembly.
DFA? • The design of the product for ease of assembly.
Where to apply? 1. To the design team in simplifying the product structure, to reduce manufacturing and assembly costs, and to quantify the improvements by using concurrent engineering approaches. 2. As a tool for benchmarking to study competitor’s products. 3. As a should-cost tool to help negotiate suppliers contracts.
If the cost of making a change to a product DFMA during its conceptual design phase is RM1K, Then the cost of makingthe the awareness same change • Intended to increase after the drawings are released and the initial of engineering design team to the prototype are fabricated is approximately need for concurrent product and RM10K, process development. If this same change is not applied until the • production Design process wherethe about run hasisstarted, cost80% impact of product’s total costs are will be approximately RM100K, determined. If the need for the design change is not • The recognized after thechanges product has cost of making to been a purchased, theittotal cost will be approx.the 1000 product as progresses through times more than during conceptual product development process design review. increases by orders of magnitude at
The Six Basic Considerations
The Ten Commandments
The Ten Commandments
1. Simplicity
How to keep part count minimum? • Key principles revolve around THREE questions:
If all answers is NO
The part’s function can be combined with another existing part
The effects of reduced part counts?
Why do we need fastener?
Why fasteners should be minimized? PROTOTYPE DESIGNS MAY REQUIRE ADDITTIONAL FASTENERS AND INTERFACES TO TEST VARIOUS DESIGN OR COMPONENT OPTIONS
PRODUCTION DESIGN SHOULD BE STRIPPED OF ANY EXCESSIVE FASTENERS
Minimum Orientations • Guiding principle are: – To create a design that can be easily assembled with minimum use of special tooling. – To always use gravity to aid you in assembly.
• Minimizing number of fasteners will obviously headed for minimizing number of orientations needed.
Multifunctional Parts • Is a primary method of reducing the total parts count. • Thus, enhancing design simplicity.
Modular Subassemblies • Good design method to predesigned for continuous product improvement through block upgrades. • Promote similar product line enhancements over time. • As new technology moves into practice and becomes cost effective, modular subassemblies can be easily replaced to provide expanded capabilities, higher processing speeds, market competitiveness or more economical substitutions.
However, • It may increase the total part count of the original product. • Positive trade-off could yet be achieved by the added ease and speed of implementing improvements for many products or product families.
1. Use Standard Materials Components and Designs • Its describe the sixth commandment – STANDARDIZE • Design reuse – Most cost-effective method • By defining company-or product family-related standard materials, standard parts, specific design process standards. – Reduce cost and TTM, while reliability will be maximized.
• The key element of standardization; – Establish the discipline within the organization to keep the standards current and readily available to the PD team. – Enforcing their effective and consistent use.
1. Specify Tolerances • Embodied in seventh commandment – Avoid Difficult component. • It is based on process capability not from design engineer’s affinity. • CE approaches in PD team is the most effective way to achieve. – Design Engr.@Manu. Engr.
1. Use of Common Materials • The fifth design consideration – use of the materials most processed. • Materials that are commonly machined or processed should be the first choice for various components. • Exotic or state-of-the-art processes or materials should be avoided. • To preclude extended process activities – C↑,TTM↑, Quality↓, & Reliability↓
1. CE Collaboration • The sixth design consideration. • Its essential for the design team to include cross-functional personnel such as; – Manufacturing engineers – Quality engineers – Procurement specialists
• To ensure all the appropriate design trade-offs are properly analyzed and selected.
• The traditional ‘Over-the-wall’ approach is guaranteed to produce product attributes that contribute to Higher production cost & Longer TTM.
The Final Three Design Commandment
True learning is based on discovery by mentoring rather than the transmission of knowledge (John Dewey)
Introduction • Is a combination between DFM & DFA DFM
Design for Manufacture Manufacturing of individual component parts of a product or assembly
DFA
Design for Assembly Addition or joining of parts to form a complete product
DFM? • The design for ease of manufacture of the collection of parts that will form the product after assembly.
DFA? • The design of the product for ease of assembly.
Where to apply? 1. To the design team in simplifying the product structure, to reduce manufacturing and assembly costs, and to quantify the improvements by using concurrent engineering approaches. 2. As a tool for benchmarking to study competitor’s products. 3. As a should-cost tool to help negotiate suppliers contracts.
If the cost of making a change to a product DFMA during its conceptual design phase is RM1K, Then the cost of makingthe the awareness same change • Intended to increase after the drawings are released and the initial of engineering design team to the prototype are fabricated is approximately need for concurrent product and RM10K, process development. If this same change is not applied until the • production Design process wherethe about run hasisstarted, cost80% impact of product’s total costs are will be approximately RM100K, determined. If the need for the design change is not • The recognized after thechanges product has cost of making to been a purchased, theittotal cost will be approx.the 1000 product as progresses through times more than during conceptual product development process design review. increases by orders of magnitude at
The Six Basic Considerations
The Ten Commandments
The Ten Commandments
1. Simplicity
How to keep part count minimum? • Key principles revolve around THREE questions:
If all answers is NO
The part’s function can be combined with another existing part
The effects of reduced part counts?
Why do we need fastener?
Why fasteners should be minimized? PROTOTYPE DESIGNS MAY REQUIRE ADDITTIONAL FASTENERS AND INTERFACES TO TEST VARIOUS DESIGN OR COMPONENT OPTIONS
PRODUCTION DESIGN SHOULD BE STRIPPED OF ANY EXCESSIVE FASTENERS
Minimum Orientations • Guiding principle are: – To create a design that can be easily assembled with minimum use of special tooling. – To always use gravity to aid you in assembly.
• Minimizing number of fasteners will obviously headed for minimizing number of orientations needed.
Multifunctional Parts • Is a primary method of reducing the total parts count. • Thus, enhancing design simplicity.
Modular Subassemblies • Good design method to predesigned for continuous product improvement through block upgrades. • Promote similar product line enhancements over time. • As new technology moves into practice and becomes cost effective, modular subassemblies can be easily replaced to provide expanded capabilities, higher processing speeds, market competitiveness or more economical substitutions.
However, • It may increase the total part count of the original product. • Positive trade-off could yet be achieved by the added ease and speed of implementing improvements for many products or product families.
1. Use Standard Materials Components and Designs • Its describe the sixth commandment – STANDARDIZE • Design reuse – Most cost-effective method • By defining company-or product family-related standard materials, standard parts, specific design process standards. – Reduce cost and TTM, while reliability will be maximized.
• The key element of standardization; – Establish the discipline within the organization to keep the standards current and readily available to the PD team. – Enforcing their effective and consistent use.
1. Specify Tolerances • Embodied in seventh commandment – Avoid Difficult component. • It is based on process capability not from design engineer’s affinity. • CE approaches in PD team is the most effective way to achieve. – Design Engr.@Manu. Engr.
1. Use of Common Materials • The fifth design consideration – use of the materials most processed. • Materials that are commonly machined or processed should be the first choice for various components. • Exotic or state-of-the-art processes or materials should be avoided. • To preclude extended process activities – C↑,TTM↑, Quality↓, & Reliability↓
1. CE Collaboration • The sixth design consideration. • Its essential for the design team to include cross-functional personnel such as; – Manufacturing engineers – Quality engineers – Procurement specialists
• To ensure all the appropriate design trade-offs are properly analyzed and selected.
• The traditional ‘Over-the-wall’ approach is guaranteed to produce product attributes that contribute to Higher production cost & Longer TTM.
The Final Three Design Commandment
True learning is based on discovery by mentoring rather than the transmission of knowledge (John Dewey)
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