Design For Manufacturing And Assembly (DFMA)

Part list table

MANUFACTURING
ITEM PART QTY
MATERIAL SUBASSEMBLY FUNCTION PROCESS/PURCHASE
NO. NUMBER .
COMPONENT
Rear Drum
Serves as the Hub
1 Cover-Hub Alloy Steel 1
inner cover
Side Rear Hub Assembly Stamping and pressing
It combines the
rear brake drum
and the rear wheel
Rear Sprocket
2 Alloy Steel 1 that receive the
& brake drum
transmitted power
from the drive Stamping and post
Rear Hub Assembly sprocket machining
Covers the Brake
Brake Drum drum from outside
3 Cover Alloy Steel 1 and serves as
Plate holder for the
Rear Hub Assembly brake lever Machining
Handles the
Brake Shoe
4 Composite 2 braking of the
With Pad
Rear Hub Assembly system Catalog Purchase
Brake Lever serves as the
5 Mounting Alloy Steel 1 mount for the
Stem Rear Hub Assembly brake lever CNC machining
Positioning
Bolt Stem for the
6 Alloy Steel 1
Mounting positioning bold
Stem Rear Hub Assembly CNC machining
Rear Brake Plain
Adjusts the two-
7 Shoe Carbon 2
break shoe
SpringsX2 Steel Rear Hub Assembly Catalog Purchase
Serves as the
Rear Brake
8 Alloy Steel 1 control for the
Lever
Rear Hub Assembly brake Casting
Brake Lever Control and adjust
9 Alloy Steel 1
Spring Rear Hub Assembly the lever Catalog Purchase
NUT 0.3125-
10 Alloy Steel 1 Fastener
18-D-S Rear Hub Assembly Catalog Purchase
Create space
Drum Position between the Brake
11 Alloy Steel 1
Spacer drum and Drum
Rear Hub Assembly Cover CNC machining
BOLT 0.3125-
Retainment/
12 24x0.75x0.75- Alloy Steel 1
assembly
S Rear Hub Assembly Catalog Purchase
Brake Cable Female Shoulder
13 Female Alloy Steel 1 for the female
Shoulder Bolt Rear Hub Assembly brake cable Catalog Purchase
Brake Cable Plain control and
14 1
Bolt Spring Carbon Rear Hub Assembly adjustment of the Catalog Purchase
 Steel brake cable bolt
Transmit power
Primary Chain
from the main
15 Sprocket- Alloy Steel 1
Drive Sprocket shaft to the rear Stamping and post
21tooth
Assembly sprocket machining
Holds the
Sprocket Shaft
16 Alloy Steel 1 Drive Sprocket sprocket to the
Nut
Assembly shaft Catalog Purchase
Transmit power
from the primary
17 Chain Steel 1
sprocket o the rear
Drive Train sprocket Stamping and pressing
Bearing Carbon
18 2 House the bearing
Housing CS Steel Alloy Gear system CNC machining
Needle Reduces system
19 Steel 2
Bearing CS Gear system friction Catalog Purchase
transmit power
20 Countershaft Steel 1 from the engine to
Gear system the main shaft CNC machining
Carbon
21 C2 GEAR 1
Steel Alloy Gear system Counter gear 2 CNC machining
reduces shock in
22 Bushing CS Rubber 1
Gear system the gear system Catalog Purchase
Shaft Washer Carbon Retainment/
23 3
CS Steel Alloy Gear system assembly Catalog Purchase
Retainment/
24 Snap Ring CS Steel 5
Gear system assembly Catalog Purchase
Carbon
25 C6 GEAR 1
Steel Alloy Gear system Counter gear 6 CNC machining
Shaft Bushing reduces shock in
26 Steel 2
CS Gear system the gear system Catalog Purchase
Carbon
27 C3 GEAR 1
Steel Alloy Gear system counter gear 3 CNC machining
Slot Lock Retainment/
28 Steel 4
Washer 2 CS Gear system assembly Catalog Purchase
Carbon
29 C4 GEAR 1
Steel Alloy Gear system counter gear 4 CNC machining
Carbon
30 C5 GEAR 1
Steel Alloy Gear system counter gear 5 CNC machining
Carbon Retainment/
31 Washer 6
Steel Alloy Gear system assembly Catalog Purchase
Carbon
32 C1 GEAR 1
Steel Alloy Gear system counter gear 1 CNC machining
Ball Bearing Carbon Reduces system
33 2
CS Steel Alloy Gear system friction Catalog Purchase
Transmit power
from counter shaft
through the lock
Carbon
34 Main shaft 1 of counter gear
Steel Alloy
and main gear to
the primary
Gear system sprocket CNC machining
35 Bushing Rubber 2 Gear system reduces shock in Catalog Purchase
 the gear system
Carbon
36 M5 GEAR 1
Steel Alloy Gear system Main gear 5 CNC machining
M3 and M4 Carbon
37 1
GEAR Steel Alloy Gear system Main gear 3 and 4 CNC machining
Carbon
38 M6 GEAR 1
Steel Alloy Gear system main gear 6 CNC machining
Carbon
39 M2 GEAR 1
Steel Alloy Gear system main gear 2 CNC machining
serves as the
stopper for the
Drive Sprocket Carbon
40 1 primary sprocket
Outer Guide Steel Alloy
when the main
Gear system shaft is inserted CNC machining
control the
engagement of
41 Shifter Drum Steel 1 different gear
ration using
Gear system engraved splines CNC machining
Component that
controls the
42 RL Shift Fork Steel 2
shifting of gears Casting and post
Gear system from left to right machining
Component that
controls the
43 C Shift Fork Steel 1
shifting of counter Casting and post
Gear system gears machining
Shifter Fork Holds the shifter
44 Steel 1
Shaft Gear system forks CNC machining
enclosure of the Casting and post
45 Gear case Steel Alloy 1
Gear system gear system machining
Adjusts the chain
Chain
46 Steel 1 tension base on
Tensioner
Chain transmission the road terrain Catalog Purchase

Design for Manufacturing (DFM)

Dissection of the motorbike transmission system revealed several areas for improvement. The
majority of the components consists of cast or stamped steel components which allows for a high
volume of relatively cheap parts to be made. High tolerance components such as the gears, shafts
and sprockets are to be machined using CNC in order to achieve required tolerances for bearing
surfaces. The choice of CNC for the high precision part is to prevent the failure of the parts due
to disarrangement of the crystal structure arrange during the casting or stamping process, also
this also reduces the cost of production. Other component such as bolt, nut and bearing are to be
purchase using the its specification to save the time and cost of production.

Design for Assembly (DFA)

Dissection of the complex chain transmission system show inconveniences that negatively affect
assembly time, assembly worker training and labor cost. It is likely several of these
inconveniences are a result of the fact that assembly is completed by the customer as well as
standard bike specific tooling. This requires an experienced user to install the chain transmission
system correctly as there are many components with no clear assembly order, especially in the
bearings installation. This was easily addressed through a clearance fit on the shaft. Additionally,
the use of unnecessarily thin retaining rings and customized sprocket fasteners slow down the
assembly process and required special tool which in turns result in extra cost has been eliminated
with easily accessible fasteners. Though it may the relative standard in the biking industry for
enthusiasts or shops, it certainly inconveniences an average user looking to conduct maintenance
or repair. Also, integrated washer/nuts are used to hold the wheel to the frame, minimizing the
number of fasteners on a part which is likely removed often. The rear chain sprocket was in such
a way that it requires no need to fastened it to the brake drum. This reduces the time spent on
repair and assembly. The adjustment of the chain tension using the slot on the rear frame has
been replaced by a terrain and manual adjusted tension system.