CONFIDENTIAL DPP D2 (b)

DMN40353
Product Design & Development
July – Dec 2022

MAJLIS AMANAH RAKYAT

BAHAGIAN KEMAHIRAN DAN TEKNIKAL
UNIT PENILAIAN DAN PERSIJILAN

PRACTICAL PROJECT 2 SHEET

JULY - DEC 2022 SESSION

COURSE : DMN40353 – PRODUCT DESIGN &

DEVELOPMENT
DATE :
DURATION : 2 WEEKS
PROGRAMME : DKN

DO NOT OPEN THIS QUESTION BOOKLET UNTIL

YOU ARE TOLD TO DO SO

Instructions:
1. This question booklet consist of 1 (ONE) question.
2. Answer all of the questions your own answer sheets.
3. Bind together the answer sheets with this question booklet.

This booklet contains 3 printed pages

[Next Page
©2022 Hak Cipta KKTM Kuantan CONFIDENTIAL
 DPP D2 (b)

KOLEJ KEMAHIRAN TINGGI MARA

KUANTAN, PAHANG

PRACTICAL PROJECT 2 SHEET

PROGRAMME: DKN

SESSION: JULY – DEC 2022 SEMESTER: 3

DMN40353 / PRODUCT DMN40353 -
CODE/COURSE: SHEET NO:
DESIGN & DEVELOPMENT PPS 02
NO OF STUDENTS: WEEK: 14

DURATION: 2 WEEKS VENUE:

LECTURER: MOHD NAZRUL IKRAM BIN MOHD ATAN

TOPIC : 9.0 Design For Assembly (DFA)

9.1 Introduction
9.2 DFA General Guidelines
9.3 Where DFA fits in the design process
SUB-TOPIC : 9.4 Design Guidelines for Part Handling
9.5 Design Guidelines for Insertion and Fastening
9.6 DFA Methods (Boothroyd)

By completing this project, students should be able to:

a. apply DFA as a tool in reducing the number of parts.
b. optimize the assembly operation process for a product.
c. simplify product handling for a product
LEARNING
OUTCOME : d. analyze the design for assembly efficiency,
e. critique the design from an assembly point of view,
f. redesign the part for improved assembly operations,
g. quantify the benefits of the re-designed part.

Page 1 of 3
 DPP D2 (b)

TASK/EXERCISE :

1. Instruction:

Select a suitable product (the total parts should be more than 20 items where the
ratio of parts to each group member is 2:1). Disassemble the product and count
the total number of parts. By using the General Guidelines for Manual Assembly,
critique each part in design. Classify each part for manual handling and for
insertion/fastening. Estimate the assembly time for this product (assuming
complete manual assembly). Identify the minimum number of theoretical parts in
the design. Calculate the design efficiency.

Modify the design to improve the assembly efficiency. Repeat the calculations of
efficiency, classifications and assembly time for the new design to show how your
design is in improvement.

To complete this project is recommended to use DFA Methods (Boothroyd) as a

method to gain the result.

2. Assessment:
Write a report and present your findings. Each group member must participate in
all activities regarding completing this task. The marks distribution is shown below:
a. Report 80%
b. Presentation 20%

3. Deliverables:
A formal report including the following:

NO. ITEMS MARKS

1 Introduction & Objective. 5

2 Product to be studied & number of parts in the original 5

design.
3 Written critique of each part. 5
Classification of each part (manual handling and
4 5
insertion/fastening). For the original design.
5 Estimated assembly time for the original design. 5
6 Design efficiency of the original design. 5
Redesign of the product (description, justification and
7 20
sketches – no need for detailed dimensioned drawings)
Classification of each part (manual handling and
8 5
insertion/fastening) for the new design
9 Estimated assembly time for the new design. 5

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 DPP D2 (b)

10 Design efficiency of the new design. 5

Discussion – comparison of the new design with the old
11 5
design (quantitative and qualitative)
12 Conclusions 5
13 References & Appendices 5

4. Duration:
The report should be submitted TWO (2) weeks prior receiving this assignment
instruction. A presentation on the finding progress of the project will be conducted
a week earlier than the due date.

5. Penalty

Criteria Deduction of Marks

Late project report submission 5%
No front page attached 2%
Report submitted not tidy 2%
Copy from other report/group 20%

REFERENCE

1. G. Boothroyd, P. Dewhurst, W. Knight, (2002), Product Design for

Manufacture and Assembly 2nd Edition Revised and Expanded, Marcel
Dekker.
2. A. Redford, J. Chal (1994) Design for Assembly Principles and Practice,
McGraw Hill Book Company.
3. K.T. Ulrich, S.D. Eppinger, (2004), Product Design and Development,
3rd Edition, McGraw Hill Irwin.
4. G. Boothroyd, (1992), Assembly Automation and Product Design,
Marcel Dekker
5. J.R.Lindbeck, R.M. Waygant (1995), Product Design and Manufacture.
Prentice Hall.

Prepared by : Approved by :

Signature : Signature :

Name : Name :
Designation : Designation :
Date : Date :

Page 3 of 3
 DPP D3
PRACTICAL PROJECT REPORT

KOLEJ KEMAHIRAN TINGGI MARA

KUANTAN PAHANG

TITLE

PRACTICAL PROJECT 2

SESSION: JUL – DEC 2013

NAME

MATRIX NO SEMESTER

CODE & SUBJECT

LECTURER
SUBMISSION DATE