Professional Documents
Culture Documents
MANUFACTURING
AND ASSEMBLY
Index
What is DFMA? Introduction to DFM
Methodology Major DFM objectives
Principles of DFMA Estimating Manufacturing Costs
Introduction to assembly Whys use DFMA?
Design for assembly Reasons for not implementing DFMA
Which parts are essential? Case study
DFA Index Other example-Reticle assembly for a thermal gunsight
Throwback DFMA Software
Bibliography
What is DFMA?
A set of guidelines developed to ensure that a product is designed so that it can
be easily and efficiently manufactured and assembled with a minimum of effort,
time, and cost.
Products designed using DFMA principles should have higher quality and
reliability than others.
DFMA also ensures that the transition from the design phase to the production
phase is as smooth and rapid as possible.
What is DFMA? (contd)
It is a concurrent engineering team approach.
The best results occur when DFMA is used in the product conceptual stage.
➢ The final cost of a product is directly proportional to the number of parts. As the
number of parts is reduced, product quality and reliability typically increase
➢ If the answer to these three questions is "NO", then the possibility of combining the
part with other parts should be considered.
2. Make Parts Multi-Functional
Multi-functional parts combine several functions into one part and reduce
complexity.
3. Design parts to be self-aligning
and self-locating.
size slipperiness
sharpness flexibililty
6. Eliminate interfaces
• Mistake-proofing
8. Maximize part symmetry if possible or make parts
obviously asymmetrical.
• Make components fit either way round • These irregularly-sized and spaced holes force the
whenever you can. worker to figure out which way it fits
• Ideally, parts will have rotational and end-to-end • The addition of a flat side or similar feature helps to
symmetry. achieve correct orientation during manual assembly
(but symmetry would probably be better)
9. Use Standard Parts and Hardware
Reduces the number of tools required for assembly and lowers assembly cost.
In order to facilitate the use of standard parts, the design team should utilize
various resources such as the preferred parts lists, standard parts manuals, vendor
catalogs, trade magazines, etc.
10. Simplify and Optimize the Manufacturing Process
Simplification and optimization of the manufacturing process reduces recurring
direct and overhead costs.
Avoiding, where possible, processes that are difficult to control (i.e., welding,
brazing, etc.).
Simplifies the product structure since the total number of parts in a product is a key
indicator of design quality.
Both the Boothroyd & Dewhurst, and Lucas methodologies use the idea of
fundamental or essential parts.
All non-essential parts should be evaluated in case they can be designed out.
The Lucas methodology labels parts as ‘A’ (essential) and ‘B’ (target for
designing out).
Boothroyd & Dewhurst use ‘1’ and ‘0’, but the result is similar.
DFA Index
❖ An essential ingredient of the DFA method.
❖ DFA index is the assembly time for an "ideal" design divided by the total
assembly time and expressed as a percentage.
❖ The DFA index is a figure obtained by dividing the theoretical minimum
assembly time by the total assembly time.
The equation for calculating the DFA index Ema is,
Where,
Ema = Nmin .ta Nmin : minimum itemcount
tma ta : theo. minimum assembly time
tma : total assembly time
#Throwback…
The first success resulting from the application of DFA in industry were reported in an article in
Assembly Engineering.(late 1970’s)
In the article, Sidney Liebson , corporate director of manufacturing for Xerox suggested that
‘’DFA would save his company hundreds of millions of dollars over the next ten years.’’
U.S. designers preferred to use the new computers rather than perform hand calculations to
analyze their designs for ease of assembly. As a result, engineers at IBM and Digital funded the
development of versions of the DFA software to run on their own company products.
A major breakthrough in DFA implementation was made in 1988 when Ford Motor Company
reported that DFA software had helped them save billions of dollars on their Taurus line of
automobiles.
Introduction to DFM
DFM is the method of design for ease of manufacturing of the collection of parts.
Like DFA ,DFM also shortens the product development cycle time.
Increased Reliability
Another reason why careful consideration of manufacture and assembly should be considered early in the
design cycle is because it is now widely accepted that over 70% of final product costs are determined during
design.
The second step in an analysis is Design for Manufacture (DFM).
By using DFM, early cost estimates for the parts are obtained for both the
original design and the new design in order to make trade-off decisions.
During this process the best materials and processes to be used for the various
parts are considered.
This is an indication that it is important not only to know the total estimated
manufacturing cost of an item but, more importantly, to know the cost of
providing the various features.
This case study is typical in the sense that although DFA means design for
assembly, the results of improving assemblability usually manifest themselves
in significant reductions in part manufacturing costs.
DFMA Software
Boothroyd Dewhurst, Inc. has developed a software package to implement DFMA
techniques.
Calculates the costs involved for different materials and manufacturing processes as well
as identify areas where the number of parts can be reduced.
Easily considers the impact of using alternative materials and manufacturing processes.
Documented significant reductions-
parts count and cost (51% and 37%)
time to market (50% faster)
assembly time (62%)
manufacturing cycle time (57%)
improved quality and reliability (68%) by system users.
Bibliography
capacify.wordpress.com
www.slideshare.net
Product Design for Manufacture and Assembly: Second Edition, Revised and
Expanded, Geoffrey Boothroyd, Peter Dewhurst, and Winston Knight
scholar.google.co.in
www.dfma.com
“Thebestdesignisthesimplestonethatworks”
-AlbertEinstein
THANK YOU!!