#03:

Product Design &

Assembly Disassembly

Manufacturing System Laboratory

Department of Industrial Engineering
Institut Teknologi Sepuluh Nopember

© 2023
Outline

Product CAD/CAM/ Rapid Assembly Disassembly

Specification CAE Prototyping
Product Life
Cycle
Product Specification
Product Specification (2)
Design?

“A creative process in which we use our intuition and analytical ability to understand the opportunities
and constraints business goals, competitive markets, customer needs, and technologies present, then
envision, communicate, and realize practical solutions that meet customer needs and create business
value”.
(Pabini, BMC Software)

“Design has two important goals: delivering a good solution—getting

the design right—and solving a significant and meaningful
problem— getting the right design”.
(Steve Baty, Meld Studios)
Design Process
Market research

Specifications

Measuring the
design against
spec

Documenting
Product Design Phase (Ulrich & Eppinger)

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

Concept System-Level Detail Testing and Production
Development Design Design Refinement Ramp-up

Mission Development
Statement Plan
Establish Generate Set Plan
Identify Select a Test
Customer Target Product Product Product Final Downstream
Needs Specs Concepts Concept Concept Specs Development

Perform Economic Analysis

Benchmark Competitive Products
Build and Test Models and Prototypes

Concept Development

Source :Exhibit 3 Chapter 5 Ulrich & Eppinger

Needs and Specifications
• What does customer need? ➔ “voice of customer”.

Metric/
yes
What IF Successful
Values
(Need) Product
no

• Product Metrics → Describe the characteristics of the products, such as size, complexity, design
features, performance, efficiency, reliability, portability, etc.
• “Value comes from solving user’s problems. The more you understand about users and their
problems, the easier it is to discover a great product / market fit.” — Adrian Howard (Agile/UX)
Quality Function Deployment
Quality Function Deployment (QFD) is a structured approach to defining customer needs or requirement
s and translating them into specific plans to produce products to meet those needs.
QFD – Elements of System Thinking

a. Understanding 'true' customer needs from the customer's perspective.

b. What 'value' means to the customer, from the customer's perspective.
c. Understanding how customers or end users become interested, choose, and are satisfied.
d. Analyzing how do we know the needs of the customer.
e. Deciding what features to include.
f. Determining what level of performance to deliver.
g. Intelligently linking the needs of the customer with design, development, engineering, manufac
turing, and service functions.
h. Intelligently linking Design for Six Sigma (DFSS) with the front end Voice of Customer analysis
and the entire design system.
4 Phases of QFD
• Define & prioritize customer
needs
• Analyze competitive opportu-
nities
• Plan a product to respond to
needs and opportunities
• Establish critical characteris-
tic target values
• Identify critical parts &
assemblies
• Flowdown critical product
characteristics
• Translate into critical part
/assy characteristics &
target values
• Determine critical pro • Determine critical part and
cesses & process flow process characteristics
• Develop production • Establish process control
equipment require- methods & parameters
ments • Establish inspection & test
• Establish critical methods and parameters
process parameters
Courtesy : http://www.systems2win.com/solutions/QFD.htm
Example
CAD/CAM/CAE
CAD 2D
CAD 3D
3D SOLID MODELLING
CAD

CAD (Computer Aided Design) is the use of computer technology for design and design document
-tation.
CAD is the use of computer programs to create two- or three-dimensional (2D or 3D) graphical
representations of physical objects.
CAD is also used to design physical products in a wide range of industries, where the software
performs calculations for determining an optimum shape and size for a variety of product and in-
dustrial design applications.

BENEFIT ?
✓ Better visualization.
✓ Greater accuracy.
✓ Easier and robust documentation.
✓ Easy re-use of design data and best practices.
CAD (2)

Software :
Pro/ENGINEER
AutoCAD
Solid Works
Catia
Unigraphics
ProgeCAD
ZWCAD
Mechanical Desktop
CAM

CAM (Computer Aided Manufacturing) is a technology which involves computer systems that
involve, plan and control manufacturing process.
CAM (2)

Software :
NX CAM and CAM Express
NX Tooling and Fixture Design
Parasolid (3D)
D-Cubed Components
SOLIDCAM
SURFCAM
MasterCAM
SmartCAM
HSM Works
CAE
CAE (Computer Aided Engineering) is the use of computer software to simulate performance in
order to improve product designs or assist in the resolution of engineering problems for a wide
range of industries. This includes simulation, validation, and optimization of products, processes,
and manufacturing tools.

BENEFIT ?

✓ Design decisions can be made based on their impact on performance.

✓ Designs can be evaluated and refined using computer simulations.
✓ CAE can provide performance insights earlier in the development process.
✓ CAE helps engineering teams manage risk and performance implications.
✓ Integrated CAE data and process management extends the ability to effectively leverage
performance insights and improve designs to a broader community.
✓ Warranty exposure is reduced by identifying potential problems.
CAE (2)

Software : Parasolid (3D)

NX CAE ANSYS
NX Nastran ADAMS
LMS Virtual Lab Moldflow
LMS Samtech ABACUS
LMS Imagine Lab Symulation
Femap Abaqus
Solid Edge Simulation
D-Cubed Components
CAD → CAM

DXF
PARASOLIDS
IGES
STL

CAD CAM
model program
NC Code

NC
Code
CAE
Thermal Analysis
Pro/Engineering
Menu Manager
Application Manager Message Area Right Toolbar
Menu Bar

Top Toolbar

Model Tree

Main Graphics
Window
Default Datum
Coordinate Planes
System
CAD, CAM, CAE

CAE Conceptu

Data
Thickness al Design Product CAD
Design Dimension

Simulation
Material
Planning

CAM
Material
handling
- Assembly
Method

Part

base
Jigs and Specificati-
fixtures on

Automatic Part
Assembly Automatic Assembly
Cutting
CIM
Example : Mobile Phone
Finite Element Analysis
Injection Molding Simulation
Prototype
Rapid Prototyping

▪ Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part
or assembly using three-dimensional computer aided design (CAD) data.

▪ Rapid prototyping helps companies turn great ideas into successful products faster than ever before.
Rapid Prototyping - Benefit

✓Enables fast, frequent revisions based on real-world testing and feedback.

✓Visualization, verification, and design optimation.
✓Simultaneous engineering.
✓Form-fit-function.
✓Marketing study – customer preference.
Medical Fields

Models Cerebral Arterio-venous Malformation and surrounding skull (

data generation: CT Angiogram)
Rapid Prototyping Process

CAD solid model

‘.STL’ file

Slicing the file

Final build file

Fabrication of part (pembuatan part)

Assembly ?

The assembly process is the process by which an assembly is put together.

Assembly process is a manufacturing process in which interchangeable parts are add
ed to a product in a sequential manner to create an end product.
Assembly Line

An arrangement of workers, machines, and equipments in which the product being as

sembled passes consecutively from operation to operation until completed.
A sequence of machines, tools, operations, workers, etc. in a factory, arranged so that
at each stage a further process is carried out.
Manual Assembly Line

Factors favoring the use of manual assembly lines include the following:
a. Demand for the product is low or medium.
b. The products made on the line are identical or similar.
c. The total work required to assemble the product can be divided into small work
elements.
d. It is technologically impossible or economically infeasible to automate the
assembly operations.
Manual Assembly Line - Benefits

Specialization of labor ➔ division of labor.

Interchangeable parts.
Work flow principle.
Line pacing.
Manual Assembly Lines - Configuration

• Asby = assembly
• Man = manual
• Sta = work station
• N = number of station on the line
Manual Assembly Lines - Products

Audio equipment Furniture Pumps

Automobiles Lamps Refrigerators
Cameras Luggage Stoves
Cooking ranges Microwave ovens Telephones
Dishwashers Personal Computers Toasters

Dryers (laundry) Printers Trucks, light and heavy

DVD Players Monitors Video game consoles
Electric motors Power tools (drills, saws, etc) Washing machines
Typical Assembly Operations

Application of adhesive Expansion fitting applications Snap fitting of two parts

Application of sealant Insertion of components Soldering

Arc welding Press fitting Spotwelding

Brazing Printed circuit board assembly Stapling

Cotter pin applications Riverting and eyelet applications Stitching

Crimping Shrink fitting applications Threaded fastener applications

Disassembly ?
The disassembly is the process of systematic removal of desirable constituent
parts from an assembly while ensuring that there is no impairment of the parts
due to the process. There are both economic and environmentally sound reaso
ns for disassembly :

Discontinued products ➔ A suddenly discontinued product line can lead to

excess inventory of undesirable assemblies.
Reduction in lead time ➔ Certain products might have to be disassembled in
order to recover some of their subassemblies / components which are scarce
and are in urgent demand by some other products.
Forced disassembly ➔ A plant may be forced to disassemble inventories
(before discarding) in order to comply with recycling regulations imposed by
governments.

Brennan, Louis; Surendra M. Gupta; Karim N. Taleb. Northeastern University Boston - USA
Operations Planning Issues in an Assembly/Disassembly Environment (1994)
Issues and Research Needs ?
TECHNICAL PROBLEMS
Ease of separation → design for ease of separation, handling, cleaning
Low energy usage
New fasteners
Precision moulds
Materials selection
Parts consolidation and product structure compression
Technical problem with existing products

Brennan, Louis; Surendra M. Gupta; Karim N. Taleb. Northeastern University Boston - USA
Operations Planning Issues in an Assembly/Disassembly Environment (1994)
Issues and Research Needs ? (2)
OPERATIONAL PROBLEMS
Accumulations
Location problems
Networking problems
Resource availability and allocation problems
Scheduling problems
Added confusion
Buffer stock location (s)
Alternative disassembly sequences
Implementation and transitional problems

Brennan, Louis; Surendra M. Gupta; Karim N. Taleb. Northeastern University Boston - USA
Operations Planning Issues in an Assembly/Disassembly Environment (1994)
Operational Impact of Incorporating Disassembly

Impact on product cost

Impact on maintenance
Impact on financial decisions
Impact on capacity and storage requirements

Brennan, Louis; Surendra M. Gupta; Karim N. Taleb. Northeastern University Boston - USA
Operations Planning Issues in an Assembly/Disassembly Environment (1994)
Work Transport Systems

Manual methods
• In manual work transport, the units of product are passed from station to station by the
workers themselves.
• Problem ➔ starving and blocking

Mechanized system
• Powered conveyors and other types of mechanized material handling equipment are widely
used to move units along a manual assembly line.
• Work transport system ➔ continuous transport, synchronous transport, and asynchronous
transport.
Mechanized System
Work Transport System
Continuous transport
Synchronous transport
Asynchronous transport
Material Handling Equipment
Overhead trolley conveyor
Belt conveyor
Roller conveyor
Drag chain conveyor
Walking beam transport equipment
Rotary indexing mechanism
Power and free overhead conveyor
Cart on track conveyor
Powered roller conveyor
Automated guided vehicle system
Monorail system
Chain driven carousel system
Line Balancing

A production strategy that involves setting an intended rate of production for required materials to be
fabricated within a particular time frame. In addition, effective line balancing requires assuring that every
line segment’s production quota can be met within the time frame using the available production capacity
(Dictionary)

Line balancing is the process of assigning tasks to workstations, so that workstations have approximately
equal time requirements. We use line balancing to minimize idle time and balance bottlenecks.
(Allison Pearson)
Line Balancing - Keywords

Everyone is doing the same amount of work

Doing the same amount of work to customer requirement
Variation is ‘smoothed’
No one overburdened
No one waiting
Everyone working together in a BALANCED
Example
Solution?
Line Balancing – Important

• Identify the cycle time and minimum number of work stations.

• Make assignments to work stations in order.
• Before each assignment, determine which tasks are eligible to be assigned to a workstation.
• After each task assignment, determine the time remaining at the current workstation by
subtracting the sum of task times already assigned to it from the cycle time.
• Break ties that occur using rules (depend on the algorithm chosen).
• Continue until all tasks have been assigned to work stations.
• Compute appropriate measures (percent idle time and efficiency) for the set of assignments.
Line Balancing Algorithm

Largest Candidate Rules

Killbridge Method
Ranked Position Weight
Case Study 1

Grommet : sealant like ring

Case study 1 : Precedence Diagram
Case Study 1
Ditentukan: Dengan menggunakan diagram precedence dan waktu standar sebe-
lumnya. Demand periodik – annual = 100,000 unit/tahun. Lini perakitan beroperasi 5
0 minggu/tahun, 5 shift/minggu, 7.5 jam/shift. Uptime efficiency=96%. Waktu reposisi
yang hilang =0.08 menit.

Tentukan:
(a) total waktu beban kerja,
(b) laju produksi per jam untuk memenuhi demand tahunan,
(c) waktu siklus,
(d) jumlah minimal teoritis yang dibutuhkan oleh lini perakitan,
(e) waktu kerja yang disediakan lini perakitan agar tercapai keseimbangan
.
CONTOH: SOLUSI

(a) Total waktu beban kerja adalah jumlah seluruh waktu elemen kerja yang terdapat di tabel
Twc=4.0 menit ne
Twc =  Tek
k =1
(b) Laju produksi per jam Rp =
100,000
= 53.33 unit/jam
50(5)(7.5)
Da
Rp =
50S w H sh
(c) Waktu siklus terkait dengan uptime efficiency 96%

60(0.96) 60E
Tc = = 1.08menit Tc =
53.33 Rp

(d) Jumlah minimum tenaga kerja: Twc

w* =
w* = (Minimum Integer  4.0 /1.08=3.7)=4 pekerja Tc
(e) Waktu kerja yang tersedia
Ts=1.08-0.08=1.00 min Ts = Tc − Tr
Mengukur Efisiensi Keseimbangan

Hampir tidak mungkin mencapai keseimbangan lintasan yang sempurna

• Efisiensi keseimbangan lintasan, Eb :

Twc
Eb = Sempurna: Eb = 1
wTs

•Delay keseimbangan, d:
wTs − Twc
d= Sempurna: d = 0
wTs

• Catatan Eb +d = 1
Efisiensi Keseluruhan

Faktor yang dapat mengurangi produktivitas lini perakitan manual

– Efisiensi lini (availability), E,

– Efisiensi reposisi (repositioning), Er,

– Efisiensi keseimbangan (balancing), Eb,

60E Twc Ts Tc − Tr
Tc = Eb = Er = =
Rp wT s Tc Tc
– Efisiensi total tenaga kerja
pada lini perakitan =
E  Er  Eb
Kebutuhan Tenaga Kerja

Kebutuhan tenaga kerja aktual untuk lini perakitan:

RpTwc Twc T
w = Minimal Int  = = wc
60EEr Eb Er EbTc EbTs

dimana

w=jumlah tenaga kerja yang diperlukan

Rp=laju produksi per jam, unit/jam
Twc=waktu kerja yang dibutuhkan per produk, menit/unit

60E Twc Ts Tc − Tr
Tc = Eb = Er = =
Rp wT s Tc Tc
Konveyor Bergerak Kontinyu - Pertimbangan Stasiun Kerja

Total panjang lintasan lini perakitan n

L =  Ls i
i =1

dimana L=panjang lintasan lini perakitan (m), Lsi=panjang lintasan stasiun i (m)

Kecepatan konveyor konstan: (jika part dasar tetap fixed selama perakitan)
Feed rate (kecepatan pemakanan)

fp=1/Tc
dimana fp=feed rate dari lini perakitan, produk/menit

Jarak (center-to-center) antar part utama

sp=vc/fp=vcTc
dimana sp= jarak (center-to-center) antar part utama, m/part
vc= kecepatan konveyor, m/menit
Konveyor Bergerak Kontinyu – Waktu Toleransi

Didefinisikan sebagai waktu yang diperlukan unit kerja untuk berada dalam batasan area stasiun kerja

Menyediakan kemungkinan variasi produk ke produk dalam waktu pekerjaaan di sebuah stasiun kerja

L
Tt = s
vc
dimana
Tt = waktu toleransi, menit;
Ls = panjang lintasan stasiun kerja, m (ft);
vc = kecepatan konveyor, m/menit (ft/menit)
Konveyor Bergerak Kontinyu – Elapsed Time

Waktu yang diperlukan oleh unit kerja berada pada lini perakitan

ET = L
= nTt
vc
dimana
ET = total waktu yang diperlukan (elapsed time), menit;
Tt = waktu toleransi, menit;
L = panjang lintasan lini perakitan, m (ft);
vc = kecepatan konveyor, m/menit (ft/menit)
Fungsi Tujuan Keseimbangan Lintasan

Untuk mendistribusikan jumlah beban kerja pada lini perakitan serata mungkin pada sejumlah pekerja yan
g ada

Minimasi (wTs – Twc)

atau
w
Minimasi  (T
i =1
s − Tsi )

Konstrain:
(1)
T
ki
ek  Ts

(2) semua ketentuan presedence ditepati/ditaati

Exercise

CV K4K1 is a sport shoemaker. Nowadays, the company launch Product B which is a new version
of Product A with some improvement. You are appointed as a manufacturing system consultant t
o provide a production plan. Below is the data for the next 6 months (in pair)

April May June July August Sept

120 140 125 130 150 110

You have to:

a. Identify the customer needs and the priority of need.
b. Create the bill of material.
c. How is the implementation of CAD, CAM & CAE.
d. What is the criteria of choosing the packaging.