Chapter 12

Assembly

12.1 ASSEMBLY PROCESSES

Note: Much of the material on assembly in this book is based on data and other
information extracted primarily from the works in the list of references. Readers
are urged to consult these original references, especially the pioneering work of
G. Boothroyd, for more detailed information and analysis.
The manufacturing process of assembly is generally thought of as consisting
of two distinct operations: handling followed by insertion. Both handling and
insertion can be done either manually or automatically.
In the case of manual handling, a human assembly operator stationed at
a workbench (Figure 12.1) reaches and grasps a part from a bin, and then
transports, orients, and prepositions the part for insertion.
In the case of automatic handling, parts are generally emptied into a parts
feeder, such as a vibratory bowl feeder (Figures 12.2 and 12.3), which contains
suitable orienting devices (Figure 12.4) so that only correctly oriented parts exit
the feeder in preparation for insertion. Feedtracks are then used to transport the
correctly oriented parts from the feeder to an automatic workhead. Escapement
devices release the parts to the workhead.
In manual insertion, the human assembly operator places or fastens the
partes) together manually. Although power tools may be used, the process is still
essentially one of manual insertion under human control.
When automatic insertion is used, automatic workheads, pick-and-place
mechanisms, and robots are utilized.

12.2 QUALITATIVE GUIDELINES ON DESIGN FOR

ASSEMBLV (DFA)

12.2.1 Reduce the Part Count

As pointed out by Boothroyd in Product Design [or Assembly and Assembly

Automation and Product Design, the two main factors affecting the assembly cost
of a product are (1) the number of parts contained in the assembly, and (2) the
ease with which the parts can be handled (transported, oriented, and preposi-
tioned) and inserted (placed, fastened, etc.).
It is somewhat obvious that if one product has 50 component parts and if an
alternative version of the same product has only 10 parts, then the one with the
fewer number of parts will ordinarily cost less to assemble. Thus, the best method
available for reducing assembly costs is to reduce the number of parts in the
assembly.
Part reduction can be accomplished either by the outright elimination of
individual component parts (eliminating screws and washers and using a press or

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