FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

TECHNOLOGY

SEMESTER 1 – 2021 / 2022

MMK 47703

DESIGN FOR MANUFACTURING AND ASSEMBLY

MINI PROJECT
TITLE: MECHANICAL PENCIL

STUDENT NAME MATRIC NO.

MUHAMAD ALLIF BIN DZARFAN 181402581

NURUL AUNI BINTI AHMAD MUKHIR 181402594

LECTURER NAME:

DR. MUHAMMAD HASNULHADI BIN MOHAMMAD JAAFAR

CONTENTS
PART A (EXISTING DESIGN) ................................................................................................................ 3
1.0 PRODUCT BACKGROUND ........................................................................................................... 3
1.1 BILL OF MATERIAL ...................................................................................................................... 4
1.2 FUNCTIONS EACH COMPONENT .............................................................................................. 5
1.3 PART DRAWING (SOLID WORK) ............................................................................................... 8
1.4 EXPLODED DRAWING ............................................................................................................... 13
1.5 ASSEMBLY DRAWING ............................................................................................................... 13
1.6 ASSEMBLY ANALYSIS............................................................................................................... 14

PART B (IMPROVED DESIGN) ............................................................................................................ 15

2.1 RECOMMENDATION OF IMPROVEMENT .............................................................................. 15
2.2 BILL OF MATERIAL .................................................................................................................... 16
2.3 PART DRAWING IMPROVED DESIGN (SOLIDWORK) ......................................................... 16
2.4 EXPLODED DRAWING IMPROVED DESIGN .......................................................................... 20
2.5 ASSEMBLY DRAWING IMPROVED DESIGN.......................................................................... 21
2.6 EXPLODED DRAWING EXISTING VS IMPROVED DESIGN ................................................ 21
2.7 ASSEMBLY DRAWING EXISTING VS IMPROVED DESIGN ................................................ 22
2.8 ASSEMBLY ANALYSIS FOR IMPROVED DESIGN ................................................................ 23
2.9 DISCUSSION ................................................................................................................................. 24
3.0 CONCLUSION ............................................................................................................................... 24
 PART A (EXISTING DESIGN)
1.0 PRODUCT BACKGROUND

Figure 1: Mechanical Pencil

A mechanical pencil, sometimes known as a clutch pencil, is a pencil with a "lead," which
is a removable and mechanically extensible solid pigment core. The lead, which is usually
composed of graphite, is not connected to the exterior casing and may be mechanically expanded
when the point wears away during usage. In precise drawing and rapid, tidy writing, mechanical
pencils are employed to create lines of consistent width without sharpening. Fine-art sketching has
also been done using them. They are also quite popular among students since they do not require
sharpening. Mechanical pencils were originally used in the eighteenth century, and various designs
were patented throughout the nineteenth and twentieth centuries.

This mechanical pencil has 10 main components which is:

1. Cap
2. Body
3. Grip
4. Cone
5. Pin
6. Shaft
7. Lead Sleeve
8. Gasket
9. Eraser
10. Bush
 Figure 2: Labelling Figure

1.1 BILL OF MATERIAL

Table 1.1: Bill of Material of Existing Design

No Qty Manufacturing
Component Name Material
. Process
Plastic Injection
1. Cap 1 Plastic Molding
Plastic Injection
2. Body 1 Plastic Molding
3. Grip 1 Rubber Molding
Plastic Injection
4. Cone 1 Plastic Molding
5. Pin 1 Steel Machining
Plastic Injection
6. Shaft 1 Plastic Molding
Plastic Injection
7. Lead Sleeve 1 Plastic Molding
8. Gasket 1 Rubber Molding
9. Eraser 1 Rubber Molding
Plastic Injection
10. Bush 1 Plastic Molding
 1.2 FUNCTIONS EACH COMPONENT

Table 1.2: Function of existing component

No
Part Photo and Name Function
.
1.
Cap  Cap is used to cover up the rubber to give an
extra comfort when user squeeze it.

2.
Body  The main structure of the mechanical pencil is
the body. The body is used as a base to mate with
the other component.

3.
Grip  Give an extra comfortable to the user to prevent
from slip.

4.
Cone  Used to drive charcoal stick to get a straight
direction.
5.
Pin  Used to hang the mechanical pencil at user
shirt.

6.
Shaft  Used as a space for the charcoal stick.

7.
Lead Sleeve
 Used to prevent charcoal stick from easily
break.

8.
Gasket
 Used to make sure the charcoal stick will fit
when it come out from the shaft.
9.
Eraser  Used as a correction medium to correct the
wrong writing.

10.
Bush
 Used to prevent pin from slip.
1.3 PART DRAWING (SOLID WORK)

Figure 3: Cap

Figure 4: Body
Figure 5: Grip

Figure 6: Cone
Figure 7: Pin

Figure 8: Shaft
Figure 9: Lead Sleeve

Figure 10: Gasket

Figure 11: Eraser

Figure 12: Bush

1.4 EXPLODED DRAWING

Figure 13: Exploded Drawing

1.5 ASSEMBLY DRAWING

Figure 14: Assembly Drawing

1.6 ASSEMBLY ANALYSIS

Table 1.3: DFA Table of analysis

Part Orientation Manual Manual Manual Manual Total

Part Minimum Assembly
Part Name Qty Handling Handling Insertion Insertion Operation
No. part count α β α+ β cost (¢)
code time(s) code time (s) time (s)
1. Body - base 1 1 360 0 360 10 1.5 00 1.5 3 2.25
2. Shaft 1 0 180 0 180 00 1.13 06 5.5 6.63 4.97
3. Bush 1 0 180 0 180 04 2.18 30 2 4.18 3.14
4. Pin 1 0 360 360 720 30 1.95 06 5.5 7.45 5.59
5. Eraser 1 0 360 0 360 12 2.25 06 5.5 7.75 5.81
6. Cap 1 0 360 0 360 11 1.8 06 5.5 7.3 5.48
7. Gasket 1 0 180 0 180 82 5.1 20 5.5 10.6 7.95
8. Grip 1 0 180 0 180 00 1.13 30 2 3.13 2.35
9. Lead Sleeve 1 0 180 0 180 04 2.18 10 4 6.18 4.64
10. Cone 1 0 360 0 360 10 1.5 39 8 9.5 7.13

TOTAL 10 1 20.72 45 65.72 49.31

DESIGN EFFICIENCY CALCULATION ASSEMBLY COST (if operator salary is RM 27.00 per hour.)

TMPC x 3 / Total Time Assembly cost = assembly time x labor rate

= 1 x 3 / 65.72 =49.31 x 27 / 3600
= 4.56% = RM0.37
 PART B (IMPROVED DESIGN)

2.1 RECOMMENDATION OF IMPROVEMENT

The lead sleeve and cone are where the improvement part has been made by combining the two
parts of it. They are not TMPC parts, although they are made of the same material. In order to
put in the lead sleeve properly, we will need a grasping tool to help us grip the small piece.

The bush component is then removed because it is not a TMPC and does not have any relative
motion on it, thus it is removed. Furthermore, it is made of the same material as the other parts,
so removing that part will not have an impact on the other parts.

Table 2.1 below show the table of comparison before and after improvement of mechanical
pencil part.

Table 2.1: Recommendation of Improvement

No. Before Improvement After improvement

1.

Table below show the combination

There is the area of before of part between lead sleeve and
combination part of cone and lead cone
sleeve

2.

There is the existing product of There is the product after remove

mechanical pencil the bush part
 2.2 BILL OF MATERIAL

Table 2.2: Bill of Material of Improved Design

No QTY Manufacturing
Component Name Material
. Process
Plastic Injection
1. Cap 1 Plastic Molding
Plastic Injection
2. Body 1 Plastic Molding
3. Grip 1 Rubber Molding
Plastic Injection
4. Cone + Lead Sleeve 1 Plastic Molding
5. Pin 1 Steel Machining
Plastic Injection
6. Shaft 1 Plastic Molding
7. Gasket 1 Rubber Molding
8. Eraser 1 Rubber Molding

2.3 PART DRAWING IMPROVED DESIGN (SOLIDWORK)

Figure 15: Cap

Figure 16: Body

Figure 17: Grip

Figure 18: Cone + Lead Sleeve

Figure 19: Pin

Figure 20: Shaft

Figure 21: Gasket

 Figure 22: Eraser

2.4 EXPLODED DRAWING IMPROVED DESIGN

Figure 23: Exploded Drawing

2.5 ASSEMBLY DRAWING IMPROVED DESIGN

Figure 24: Assembly Drawing Improved

2.6 EXPLODED DRAWING EXISTING VS IMPROVED DESIGN

Table 2.3: Exploded Drawing of Existing and Improved Design
Existing Design Improved Design
2.7 ASSEMBLY DRAWING EXISTING VS IMPROVED DESIGN

Table 2.4: Existing Design and Improve Design Result

Existing Design Improved Design
Total parts 10 8
Total operation time (s) 65.72 55.36
Assembly cost (RM) RM0.37 RM0.31
Design Efficiency (%) 4.56 5
 2.8 ASSEMBLY ANALYSIS FOR IMPROVED DESIGN

Table 2.5: DFA Table of analysis

Part Orientation Manual Manual Manual Manual Total

Part Minimum Assembly
Part Name Qty Handling Handling Insertion Insertion Operation
No. part count α β α+ β cost (¢)
code time(s) code time (s) time (s)
1. Body - base 1 1 360 0 360 10 1.5 00 1.5 3 2.25
2. Shaft 1 0 180 0 180 00 1.13 06 5.5 6.63 4.97
3. Pin 1 0 360 360 720 30 1.95 06 5.5 7.45 5.59
4. Eraser 1 0 360 0 360 12 2.25 06 5.5 7.75 5.81
5. Cap 1 0 360 0 360 11 1.8 06 5.5 7.3 5.48
6. Gasket 1 0 180 0 180 82 5.1 20 5.5 10.6 7.95
7. Grip 1 0 180 0 180 00 1.13 30 2 3.13 2.35
8. Cone + lead 1 0 360 0 360 10 1.5 39 8 9.5 7.13
sleeve
TOTAL 8 1 16.36 39 55.36 41.53

DESIGN EFFICIENCY CALCULATION ASSEMBLY COST (if operator salary is RM 27.00 per hour.)

TMPC x 3 / Total Time Assembly cost = assembly time x labor rate

= 1 x 3 / 55.36 =41.53 x 27 / 3600
= 0.05 @ 5% = RM0.31
 2.9 DISCUSSION

By combining the two components of the lead sleeve and cone, it has been possible to improve
the performance of the item. This is due to the fact that they are not TMPC parts, despite the
fact that they are manufactured from the same material. In order to properly insert the lead
sleeve, we will need a grasping tool to assist us in holding the small piece of lead. Plastic
injection molding is the manufacturing process that was used to create this component. Because
the materials are the same, the manufacturing process is the same as well, allowing for cost
savings in the manufacturing process.

The bush component has been removed from the mechanical pencil part because it is not a
TMPC and does not have any relative motion. On top of that, it is constructed of the same
material as the other components. The removal of the bush component and the combination of
the lead sleeve and cone parts will lead to a decrease in the design efficiency, assembly time,
and assembly cost of the mechanical pencil. The difference between the existing cost and the
cost of the improvement part can result in a cost savings of approximately RM0.06.

3.0 CONCLUSION

In conclusion, the Design for Manual Assembly (DFMA) method is quite effective for analyzing
the design of a mechanical pencil. This strategy is also extremely beneficial for improving the
design efficiency and operational costs of the product under analysis. Apart from that, a
comparison of design efficiency and assembly cost before and after improvement demonstrates
a significant improvement when this method is used. This is because the completed product will
have a higher level of efficiency, time, and cost due to the reduced number of parts and part
counts. By redesigning the mechanical pencil and lowering the number of components, the
DFMA can significantly reduce the overall assembly cost. Then, by reducing the part's cost, it is
possible to increase the product's reliability, hence reducing the likelihood of product failure.
Additionally, it may be stated that minimizing the number of parts increases design efficiency,
hence lowering assembly costs. The part that have been evaluated and can be combined to form
a single component is cone and lead sleeve. The bill of materials for the improved design can be
reduced from ten components in the existing product to eight components in the improved design
by combining the cone and lead sleeve components and eliminating the bush component. The
findings of this study indicate that the DFMA method is quite beneficial in terms of lowering
manufacturing costs and part count.