Design For Manufacturing

Fall2005- ENGR 3200U 1

 Product Development Process

Concept
Concept System-Level
System-Level Detail
Detail Testing
Testingand
and Production
Production
Planning
Planning Development Design Design Refinement Ramp-Up
Development Design Design Refinement Ramp-Up

How can we emphasize manufacturing issues

throughout the development process?

Fall2005- ENGR 3200U 2

Case Study: Design of General Motors
3.8-Liter V6 Engine
GM powertrain division manufacture about 3500 3.8 Liter V6 engine
every day. A strong interest in reducing the cost of engine while
simultaneously enhancing its quality.
High production
volume:
A team was formed to
improve on of the
most expensive
subassemblies in the
engine: the air intake
manifold

Fall2005- ENGR 3200U 3

Case Study: Design of General Motors
3.8-Liter V6 Engine

Original and the

redesigned
manifolds:
Molded
Thermoplastic
composite
instead of the cat
Aluminum

Fall2005- ENGR 3200U 4

Determination of Product Cost

Fall2005- ENGR 3200U 5

Design For Objective
Functions (DFX)
Design for Manufacturing (DFM), Assembly (DFA),
Quality (DFQ), and design for any other objective
functions (DFx)

Fall2005- ENGR 3200U 6

Design for Manufacturing

Design For Manufacturing (DFM), represents a new awareness of the

importance of design as the first manufacturing step.

It recognizes that:
Company can not meet quality AND cost objectives with
isolated design and manufacturing.

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 Definition
• 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.

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 Three Methods to Implement DFM

1. Organization: Cross-Functional Teams

2. Design Rules: Specialized by Firm

3. CAD Tools: Boothroyd-Dewhurst Software

Fall2005- ENGR 3200U 9

Five Steps of DFM

A cost based five steps process

for DFM is suggested:
1- Estimate the manufacturing
costs
2- Reduce the costs of
components
3- Reduce the costs of assembly
4- Reduce the cost of supporting
production
5- Consider the impact of DFM
decisions on the other factors

Fall2005- ENGR 3200U 10

 Understanding Manufacturing Costs
Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material

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Total Manufacturing Cost

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 Design for Assembly Rules
Example set of DFA guidelines
from a computer manufacturer.
1. Minimize parts count.
2. Encourage modular assembly.
3. Stack assemblies.
4. Eliminate adjustments.
5. Eliminate cables.
6. Use self-fastening parts.
7. Use self-locating parts.
8. Eliminate reorientation.
9. Facilitate parts handling.
10. Specify standard parts.
Fall2005- ENGR 3200U 13
 Design for Assembly
• Key ideas of DFA:
–Minimize parts count
–Maximize the ease of handling parts
–Maximize the ease of inserting parts
• Benefits of DFA
–Lower labor costs
–Other indirect benefits
• Popular software developed by
Boothroyd and Dewhurst.
–http://www.dfma.com
Fall2005- ENGR 3200U 14
 To Compute Assembly Time

Handling Time
+ Insertion Time

Assembly Time

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 Method for Part Integration
• Ask of each part in a candidate design:
1. Does the part need to move relative to the rest of the
device?
2. Does it need to be of a different material because of
fundamental physical properties?
3. Does it need to be separated from the rest of the
device to allow for assembly, access, or repair?
• If not, combine the part with another part in the device.

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DFA Index

N ×3
DFA index =
t

N= Theoretical minimum number of the parts. An estimation of

the results of parts integration

t= Actual time of the assembly

Fall2005- ENGR 3200U 17

 Videocassette DFM Exercise

• 2 billion worldwide annual volume

• 7 major producers of 1/2” cassette shells
• JVC licenses the VHS standard
– dimensions, interfaces, light path, etc
• VHS cassette shells cost ~$0.25 each
• What is a $0.01 cost reduction worth?

Fall2005- ENGR 3200U 18

Computer-Based Approaches to
DFM
Computer Aided DFM helps simplify the effort and shortens
the time required to implement the DFM on a daily basis

There are many Computer Aided DFA tools available.

Not many Computer Aided DFM are represented

Example:
Boothroyd Dewhurst Incorporated (BDI), sells modules for
DFA, casting, and electronic manufacturing.

Ahmad Barari, H. A. ElMaraghy, Design for Machining

Software

Fall2005- ENGR 3200U 19

Case Study: Computer Aided
Design for Machining
1- Definition of the NURBS Surface

Fall2005- ENGR 3200U 20

Case Study: Computer Aided
Design for Machining (DFMc)
2- Design Tolerance Definition
t u = 0.06 mm
t l = 0.06 mm Profile Tolerances
Rotation Tolerance about the X - axis = ±0.0001 rad
Rotation Tolerance about the Y - axis = ±0.0001 rad
Rotation Tolerance about the Z - axis = ±0.0001 rad Design Tolerances
Position Tolerance in the X - axis = ±0.1 mm
Position Tolerance in the Y - axis = ±0.1 mm
Position Tolerance in the Z - axis = ±0.1 mm

Fall2005- ENGR 3200U 21

 Case Study: Computer Aided
Design for Machining (DFMc)
3- Machine Tool Errors Modeling
⎡- (1 + (-xRz - Sxy) × yRz - (xRy + Szx) × yRy) × zTx ⎤
⎢- (-yRz - xRz - Sxy + (xRy + Szx) × (yRx + Syz)) × zTy ⎥
⎢ ⎥
⎢- (yRy + (-xRz - Sxy) × (-yRx - Syz) + xRy + Szx) × (zTz - GZ) ⎥
⎢ ⎥
⎢- yTx - (-xRz - Sxy) × (yTy - GY) - (xRy + Szx) × yTz - xTx + GX ⎥
⎢ ⎥
⎢ ⎥
⎢ ⎥
⎢ - (xRz + Sxy + yRz + xRx × yRy) × zTx ⎥
⎢ ⎥
⎢ - (-(xRz + Sxy) × yRz + 1 - xRx × (yRx + Syz)) × zTy ⎥
⎢ - ((xRz + Sxy) × yRy - yRx - Syz - xRx) × (zTz - GZ) ⎥
′ = ⎢ ⎥
PXYZWT
⎢ - (xRz + Sxy) × yTx - yTy + GY + xRx × yTz - xTy ⎥
⎢ ⎥
⎢ ⎥
⎢ ⎥
⎢ - (-xRy - Szx + xRx × yRz - yRy) × zTx ⎥
⎢ ⎥
⎢ - (-(-xRy - Szx) × yRz + xRx + yRx + Syz) × zTy ⎥
⎢ - ((-xRy - Szx) × yRy + xRx × (-yRx - Syz) + 1) × (zTz - GZ) ⎥
⎢ ⎥
⎢ - (-xRy - Szx) × yTx - xRx × (yTy - GY) - yTz - xTz ⎥
⎢ ⎥
⎢ ⎥
⎢ ⎥
⎣⎢ 1 ⎦⎥

Fall2005- ENGR 3200U 22

Case Study: Computer Aided
Design for Machining (DFMc)
Error Parameter Description Error Value

4- Machine xTx Positioning Error in X-axis Translation 0.0250 mm

Calibration Data
xTy Y Straightness in X-axis Translation 0.0450 mm
xTz Z Straightness in X-axis Translation 0.0230 mm
xRx Roll of X-axis Translation 0.000019 rad
xRy Pitch of X-axis Translation 0.000145 rad
xRz Yaw of X-axis Translation 0.000024 rad
yTx Positioning Error in Y-axis Translation 0.0300 mm
yTy Y Straightness in Y-axis Translation 0.0760 mm
yTz Z Straightness in Y-axis Translation 0.0050 mm
yRx Yaw of Y-axis Translation 0.000010 rad
yRy Roll of Y-axis Translation 0.000048 rad
yRz Pitch of Y-axis Translation 0.000072 rad
zTx Positioning Error in Z-axis Translation 0.0040 mm
zTy Y Straightness in Z-axis Translation 0.0050 mm
zTz Z Straightness in Z-axis Translation 0.0025 mm
zRx Pitch of Z-axis Translation ----
zRy Yaw of Z-axis Translation ----
zRz Roll of Z-axis Translation ----
Sxy Mutual Squareness of X and Y axes 0.000029 rad
Fall2005- ENGR 3200U Syz Mutual Squareness of Y and Z axes 0.000034 rad 23
Szx Mutual Squareness of Z and X axes 0.000019 rad
Case Study: Computer Aided
Design for Machining (DFMc)
5- Error Distribution before using DFMc tool

Fall2005- ENGR 3200U 24

Case Study: Computer Aided
Design for Machining (DFMc)
6- Error Distribution after using DFMc tool

Fall2005- ENGR 3200U 25

Design for Quality (DFQ)
Principles
Quality excellence can best be achieved by preventing problems
rather than by detecting and correcting them after they occur

Fall2005- ENGR 3200U 26

DFQ (Design For Quality):
Eliminate the need for, and
dependence upon inspection
Eliminate the need for, and dependence upon inspection to achieve
quality by building quality into the product in the first place. Design for
quality, manufacturability, assembly, maintenance, etc. Design quality
into the product, process and/or service. (In terms of CE, think of
team-oriented problem solving; teams, that have customers, suppliers,
quality, marketing, manufacturing, assembly, etc. functions
represented. Let them get involved with the design at an early stage.)

Fall2005- ENGR 3200U 27

Design for Manufacturing and
Improving Product Quality by
Preventing Defects (Poka-Yoke)
Poka-Yoke is a technique for avoiding simple human error and aiming
for zero defects at all levels of work. (Poka-Yoke means "mistake-
proofing" or "fail-safing".)

The fundamental concept is that any kind of mistake is made by

people and that people make fewer mistakes if they are supported by
a design/manufacturing/assembly system which is developed basis
that errors can always be prevented.

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Poka-Yoke Example

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