1.

0 Title : Mechanical Design for Assembly

2.0 Introduction

Design for assembly (DFA) is a process by which products are designed with ease of assembly in mind. The aim of design for assembly is to simplify the product so that the cost of assembly is reduced. However, consequences of applying DFA usually include improved quality and reliability, and a reduction in production equipment and part inventory. These secondary benefits often outweigh the cost reductions in assembly. The reduction of the number of parts in an assembly has the added benefit of generally reducing the total cost of parts in the assembly. DFA is a concept where a product is designed for ease of disassembly. Disassembly is usually required for product maintenance. The practice of DFA as a distinct feature of designing is a relatively recent development, but many companies have been essentially doing DFA for a long time. For example, General Electric published an internal manufacturing producibility handbook in the 1960's as a set of guidelines and manufacturing data for designers to follow. These guidelines embedded many of the principles of DFA without ever actually calling it that or distinguishing it from the rest of the product development process. It is important to quantify the improvements and goals of DFA. Two methods for DFA quantification considered here are the boothroyd-dewhurst method and the Lucas method. For Boothroyd-Dewhurst Method it is based on two principles which are the application of criteria to each part to determine if it should be separate from all other parts and second principle is the estimation of the handling and assembly costs for each part using the appropriate assembly process. For our case study, we used this method for a guideline to analyze the design of the cooler pad for laptop and learn how the way it assembles.

3.0 Objectives I. II. To identify the functions and the weakness for each of the component. To critique each part in the design by using the General Guidelines for Manual Assembly. III. To disassemble a product and count the total number of parts.

4.0 Procedure 1. The suitable product has been selected. 2. The product has been disassembled and the number of component is calculated. 3. Each part in the design has been criticized by using the General Guidelines for Manual Assembly (Boothroyd-Dewhurst DFMA Methodology). 5.0 Product To Be Study For this experiment, we have chosen an automation rice cooker as the product to be study.

5.1 Total Number of Component Component ID Name of Component 1 Holder 1 Image Quantity

Plastic steam vent

Body top

Rubber liner

Aluminium steel plate

Plastic casing

Bottom cover

Wire

Rice pot

10

Inner pot cover

11

Plastic ring

12

Plastic hinge

13

Spring

14

Temperature controller

15

Heater plate

16

Source port connection

17

Plastic cap

18

Connection lever

19

Beam holder

20

Rod

21

Screw

16

22

Screw

12

23

Screw

24

Hinge rod

TOTAL

50

Component ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Name of Component

Function

Weakness

Holder Plastic steam vent Body top Rubber liner Aluminum steel plate Plastic casing Bottom cover Wire Rice pot Inner pot cover Plastic ring Plastic hinge Spring Temperature contoller Heater plate Source port connection

17 18 19

Plastic cap Connection beam Beam holder

20 21 22 23 24

Rod Screw Screw Screw Hinge rod

7.0 Discussion After the product that we choose has been disassemble which is an automated rice cooker, we found that there are total of 50 numbers of components. The main parts in the automated rice cooker are the body, fan chassis, motor, wire and magnetic ring. There are also other parts in the cooler pad which support the product which is the joint, washer, blade, screw and rubber. After the disassemble, we try to identify the function of each components, this is important so that we know function of each components and how it works and also we identify the weakness of the automated rice cooker. Next, we criticize each component by using the General Guidelines for Manual Assembly (Boothroyd-Dewhurst DFMA Methodology) .This part is important, so that we can propose the way to improve the parts in order to reduce the cost and increase the performance of the automated rice cooker.

8.0 Conclusion

As a conclusion, the product is carefully disassembled and the parts were analyzed and recorded. There are total of 50 number of component in the automated rice cooker. The functions of all the part are determined through discussion among team member and critique based on the General Guidelines for Manual Assembly. Some of the part cannot be comment due to lack of skill and some part are standard design that available on market and not been manufacture in the factory.

9.0 Reference 1. http://www.machinedesign.com 2. Dr Masine Md Tap,Work Design(Module) 3. Design For Assembly (pdf)