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Introduction
The aim of design for assembly (DFA) is to simplify the product so that the cost
of assembly is reduced. However, consequences of applying DFA usually include
improved quality and reliability, and a reduction in production equipment and part
inventory. These secondary benefits often outweigh the cost reductions in
assembly.
DFA recognises the need to analyse both the part design and the whole product
for any assembly problems early in the design process. We may define DFA as "a
process for improving product design for easy and low-cost assembly, focusing
on functionality and on assemblability concurrently."
It wasn't until the 1970's that papers and books on the topic began to appear.
Most important among these were the publications of G. Boothroyd that
promoted the use of DFA in industry.
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9/20/2010 Design for Assembly
The appropriate ranges for each type of assembly method are shown
(approximately) in Figure 2.
Note that many products do not lend themselves to these guidelines. Many such
products are sold as "ready-to-assemble" kits or require that assembly be shifted
to cheaper labour markets.
design the part so that it is compatible with the robot's end effector.
design the part so that it can be fed in the proper orientation.
Boothroyd-Dewhurst Method
The analysis is generally performed using some kind of workshee (example shown
below)t. Tables and charts are used to estimate the part handling and part
insertion time. These "lookup tables" are based on a two-digit code that is in
turn based on a part's size, weight, and geometric characteristics.
Non-assembly operations are also included in the worksheet. For example, extra
time is allocated for each time the assembly is re-oriented.
Next, parts are evaluated as to whether it is really necessary (in the assembly)
by asking three questions:
The list of all parts is then evaluated to obtain the minimum number of
theoretically needed parts, denoted by Nm.
* - in column "i", use "1" to represent that a part is essential, and "0" to
represent that a part is not essential.
The method then assumes that the assembly time for a part is 3 seconds. With
that assumption, the design efficiency can be calculated as:
The charts for this process can be purchased from a company set up by Boothroyd
and Dewhurst. As well, they hold workshops and seminars across North America.
As this process can be very time-consuming, software is available to help the
design engineer. Refer to http://www.dfma.com for further information. A nice
screenshoot of the Boothroyd and Dewhurst software is available here.
Lucas Method
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