4.

12 Design for Assembly and Design for Manufacturing

Design for Assembly (DFA) concerns about design that can make assembly process ease as
possible. Two important operations that involved in DFA are handling and insertion and
fastening. This design need to focus on simplicity meaning it needs to has the requirements of
minimizing part number, part variety, simplify assembly sequences and component handling and
lastly insertion.

The general guidelines for DFA are :

1. Minimize the total number of parts

2. Minimize the assembly surface
3. Use subassemblies
4. Mistake-proof the design and assembly

As the guideline for handling are :

1. Avoid separate fasteners or minimize fastener cost

2. Minimize handling in assembly

Guidelines for insertion:

1. Minimize assembly direction

2. Provide unobstructed access for parts and tools
3. Maximize compliance in assembly
4. Provide chamfers
5. Provide clearance
6. Design a part which can be located before it is released

For BINZO the design for assembly is rather simple because it only has ten parts in total.
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.

There are five steps of DFM process :

1. Estimate the manufacturing costs

2. Reduce the costs of components
3. Reduce the costs of assembly
4. Reduce the costs of supporting production
5. Consider the impact of DFM decision on other factors.

As for BINZO to fit in the requirements for DFM injection molding manufacturing process is the
best process for this waste bin. This is because the process is suitable for the mass production of
products with complicated shapes, and takes a large part in the area of plastic processing.
Furthermore, the advantage of injection molding which is the ability to scale production in mass.
Once the initial costs have been paid the price per unit during injection molded manufacturing is
extremely low. The price also tends to drop drastically as more parts are produced.