Assignment Problem

The figure shows a drawing of a type of caster assembly that is commonly found on heavy
boxes. Evaluate the ease or difficulty of assembling the caster by using the Assembly Advisor
(Table 5.1). What suggestions would you make in the design to reduce assembly costs?

Objective

Using the Assembly Advisor to evaluate the ease or difficulty of assembling a caster which in
turn reduces the cost of assembly operations

Several things are taken into consideration when trying to reduce the assembly cost of
operations. Certain considerations like reducing part count, and reducing manual handling time.
In this context, fulfilling the principal objectives will be centered around reducing the part count
for the assembly operation.

Assembly advisor table

Handling Easily aligned and Not easily aligned or Not easily aligned
 easily inserted not easily inserted and not easily
inserted

Easy to grasp and Good Poor Costly

manipulate 4.0 8.0 13.0

Not easy to grasp Poor Costly Most costly

and 7.5 11.5 16.5
manipulate

Table 2.2: Part Classification according to advisor table

Handling Easily aligned and Not easily aligned or Not easily aligned
easily inserted not easily inserted and not easily
inserted

Easy to grasp and i. Nuts i. Nut Nil

manipulate ii. Bracket ii. Bolt
iii. Washers for iii. Plate
plate iv. Screw
v. Wheel
vi. Washer for
wheel

Not easy to grasp Nil Nil Nil

and
manipulate

Based on the initial design, the assembly time computation is

 Part name Number of Part Part design Time per part (s) Total time (s)
(s)
Bolt for wheel 1 Poor 8.0 8.0
Wheel 1 Poor 8.0 8.0
Plate 1 Poor 8.0 8.0
Brackets 2 Good 4.0 8.0
Nut for plate 6 Good 4.0 24.0
Nut for wheel 1 Poor 8.0 8.0
Washers for 6 Good 4.0 24.0
plates

Washer for 2 Poor 8.0 16.0

wheel

Screws 6 Poor 8.0 48.0

Total assembly time 152

Recommendation for reducing the assembly time is:

 Reduce Parts Counts: we can redesign the 2 nuts at the middle of the plate with their
washers in can be eliminated and replaced with groove.
 Plate should be chamfered at the edges for easy aligning, grasping and handling. A
groove should be made on either side of the plate for joining with bracket firmly. This
will enable easy alignment of the plate, screw and nut. A desired snap fit can also be
used for this purpose.
 The four nuts at the plate edges could be retained for increased strength at the joints.
 Wheel should be self-locating, Self-locating with no need to be held in place e.g.,
chamfer and recess.
 The brackets can be designed to have a protruding shaft so that the wheel can be hanged
freely before coupling with bolt and nuts. This will enable easy alignment of the wheel,
bolt and nut.
Part name Number of Part Part design Time per part (s) Total time (s)
 (s)
Bolt for wheel 1 Good 4.0 4.0
Wheel 1 Good 4.0 4.0
Plate 1 Good 4.0 4.0
Brackets 2 Good 4.0 8.0
Nut for plate 4 Good 4.0 16.0
Nut for wheel 1 Good 4.0 4.0
Washers for 6 Good 4.0 24.0
plates

Washer for 2 Good 4.0 8.0

wheel

Screws 6 Good 4.0 24.0

Total assembly time 96