BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S

VISHWAKARMA INSTITUTE OF TECHNOLOGY,

PUNE
SEMINAR PRESENTATION
TOPIC: DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)
SUBJECT: MECHANICAL SYSTEM DESIGN

TY-ME –D BATCH 3 GROUP 5

 GROUP MEMBERS:
• ME_D_59 RISHIKESH N. THAKUR
• ME_D_60 VEDANG C. THIPSAY
• ME_D_75 YASH S. WASULE
• ME_D_76 SHREYAS B. YADAV
GUIDED BY:
• ME_D_78 YASH S. SAKHALE PROF. MORESHWAR KHODKE
• ME_D_79 DEVDATTA O. ZIKRE

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

1
OUTLINE OF THE SEMINAR
• What is design for manufacturing
• What is design for assembly.
• Design for manufacturing and assembly
• DFMA guidelines
• Advantages of applying DFMA
• Disadvantages of applying DFMA
• Case study - Cost Reduction of a Diesel Engine
• Conclusion
• References

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA) 2

WHAT IS DESIGN FOR MANUFACTURING OR DFM?
• Design for Manufacturing (DFM) is the process of designing parts,
components or products for ease of manufacturing with an end goal of making
a better product at a lower cost. This is done by simplifying, optimizing and
refining the product design. 
• Five principles are examined during a DFM. They are:
1. Process
2. Design
3. Material
4. Environment
5. Compliance/Testiing

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

3
WHAT IS DESIGN FOR ASSEMBLY?
• Fewer parts less time to assemble the object. 
• DFA is a design process or concept where a product contains as little parts as possible.
Which makes it easier to assemble a product but also timesaving, also saves costs.
• Improvements in the reliability and quality of the product.
• We do have to think small to be able to reduce parts of an existing product.
• Think of components.

For Assembly principles

• Use as little number of components as possible
• Build-in fasteners. Usage of the same parts and fasteners.
• Think: modular.
• Fullproof for assembly.
• Ease of packaging.
DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)
4
DESIGN FOR MANUFACTURING AND ASSEMBLY
• Differences between design for manufacturing (DFM) and design for assembly (DFA)
• DFM is a design method to reduce the complexity of manufacturing operations and the overall cost of
production including the cost of raw materials.
• DFA is a design method to facilitate or reduce the assembly operations of parts or components of a
product.
• The difference is that one focuses on parts (DFM) and the other on part assembly (DFA).

• Why using design for manufacturing or design assembly

• It is usually accepted that 70 to 80% of production costs are determined by design decisions.
• Importance of using design for manufacturing or design for assembly.

• Design for manufacturing and assembly (DFMA), the right balance

• DFM and DFA can be contradictory.
• DFA can lead to an extremely complicated part to produce, with a high cost.
• Combined Design for Manufacturing and Assembly approach has become the standard today. 5
DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)
 DFMA GUIDELINES

Reduce The Number Of Parts:

• Fewer parts result in lower costs.

• Makes the assembly simpler.
• Less prone to defects.
• Less parts implies less purchases,
inventory, handling, processing time,
development time.
• Fewer fabrication and assembly steps
are required.
Figure 1 : Reduction in part count[1]

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

6
DFMA GUIDELINES

• Develop A Modular Designs:

• Modules simplifies manufacturing
activities such as inspection, testing,
assembly, purchasing.
• Dismantling is faster and requires fewer
tools.
• Field service becomes simple, fast and
cheap.
• It facilitates faster automation.
Figure 2 : Modularize multiple parts into single sub-assemblies [1]

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

7
DFMA GUIDELINES
• Optimize Part Handling:
• Dismantling is faster and requires fewer
tools.
• Eliminate tangling.
• Field service becomes simple, fast and cheap.
• It facilitates faster automation.

Figure 3 : Eliminate Tangling[4]

Figure 4 : Close up springs to avoid Tangling[3]

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

8
 DFMA GUIDELINES
 ELIMINATE FASTENERS
• Difficult to handle.
• Can cause jamming of components, if defective. FIGURE 4 : Depict Fasteners
Source: https://gfycat.com/discover/fasteners-gifs
FIGURE 5 : Depicts Fastener
• The cost of driving a screw can be six to ten times the Source: https://www.iconfinder.com/search?q=fasteners

cost of the screw itself.

 Solution:
• Usage of self-tapping screws.
• Use combined fasteners.
• Push-on fasteners.

FIGURE 6 : Depict Combined Fasteners [10] FIGURE 7 : Depicts Push-on Fasteners

Source: http://www.starlock.co.uk/

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

9
 DESIGN PARTS FOR SIMPLE ASSEMBLY

• Misalignment is a serious problem when parts from different

vendors are put together.
• The product should be designed for part compliance.
• Increases assembly time and cost for labour work. FIGURE 8: Depicts Assembly line
Source :https://www.iconfinder.com/search?q=fasteners
FIGURE 9 : Depicts Parts
for Simple Assembly [10]

 Solution:
• Design small parts so they can be inserted in as many ways as
possible, from both ends, if possible, with the least amount of
angular orientation.
• Adding chamfers on both mating parts.
• Design parts so they cannot be inserted incorrectly.

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA) FIGURE 10 : Depicts Parts for Simple Assembly [10] 10
 DFMA GUIDELINES
Reduce
 Reduce, Simplify and Optimize
Manufacturing & Assembly
Process Optimis
Simplify
e
• The number of processes needed to FIGURE
FIGURE 11
11 :: Depicts
Depicts Optimization
Optimization of
of process[10]
process[10]

assemble a product should be kept to (A) (B)

a minimum.
• Processes that are difficult to control,
such as welding or brazing, should be
avoided.
• Using different technology: replacing
mechanical with mechatronics.
FIGURE 12 : Depicts Reduction, Simplification and Optimization of process[11]

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

11
 Assemble in the open:
• Assembly operations – Clear view.
• Small components should not be
buried.
• Important for manual assembly.
• Decreases chances of manufacturing
defects.
Figure 13 – Do not bury small components

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

12
 Do not fight gravity:
• Assembly from bottom to top.
• Along vertical axis.
• Minimize number of insertion
Figure 14 – Vertical axis assembly
direction.
• Design first part: large and wide.

Figure 15 – First part large and wide

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

13
 Design for part identity:
• Symmetric parts are easier to handle.
• As assembly rate increases, symmetry
becomes more important.
• Asymmetry can be added to force
correct alignment and orientation.

Figure 16 – Easier alignment

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

14
 APPLICATION DESIGN FOR MANUFACTURE & ASSEMBLY
( REDUCING “REWORK” IN “DESIGN-MANUFACTURE ASSEMBLY” SYSTEM)

• Design-Manufacture-Assembly: an essential part in Product Design and

Development (PD&D) process
• Rework within “Design-Manufacture-Assembly” system significantly
influences system performance
• Benefits: involving extensive knowledge and expertise from later stages into
early design stage

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

15
 APPLICATION DESIGN FOR MANUFACTURE & ASSEMBLY
( REDUCING “REWORK” IN “DESIGN-MANUFACTURE ASSEMBLY” SYSTEM)

• Design for Manufacture and Assembly: divided in two

parts i.e., Design for Manufacture (DFM) and Design
for Assembly (DFA)
• Three stages of Detail Design- Manufacture & SCM,
and Assembly & Integration.
• Application Design for Manufacture (DFM) method to
stages of both Detail Design and Manufacture & SCM.
• Application Design for Assembly (DFA) method to
stages of both Detail Design and Assembly &
Integration.
Fig 17. Application Design for Manufacture and Assembly to Reducing "Rework"

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

16
ADVANTAGES OF APPLYING DFMA
• Possible to produce competitively priced, high performance product at a
minimal cost.
• Reduces the manufacturing cost of the product
• it helps to reduce the time to market and quality of the product
• Provides a systematic procedure for analyzing a proposed design
• Any reduction in the number of parts reduces the cost as well as the inventory.
• Encourages the dialogue between the designer and manufacturing engineer
during the early stages of design.

DESIGN FOR MANUFACTURING AND ASSEMBLY 17

(DFMA)
LIMITATIONS OF APPLYING DFMA
• Time consuming process
• Resistance to adopt new techniques
• Low assembly cost
• Low volume
• Database doesn't apply to products

Fig 18. Limitations of DFMA

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

18
 CASE STUDY - COST REDUCTION OF A DIESEL ENGINE
• This work presents a study of manufacture and assembly costs reduction in a diesel engine model that intends to make
this engine economically feasible
• Introduction to Diesel engine or engine for ignition by compression is an engine that gets the ignition without an
exterior intervention.
• After the analysis of the engine design, it was identified that the production time is appmximately 5 hours and 35
minutes, and the production capacity correspond to one engine in each 7 minutes. Firstly, the design efficiency is
calculated through the following formula: EP = 3 x NP / TM, being (EP: design efficiency, NP: parts number, and TM:
assembly time), detailed in Table 1.
• Aiming to suggest the modifications, the study is developed based on the DFMA
guidelines that are as follows:

• To develop modulate designs;

• To design multifunctional components;
• To design components of easy manufacture;
• To eliminate unnecessary adjusts and tolerances;
• To emphasize the standardization of components;
• To reduce the product parts number; Fig 19. Engine Assembly for case study

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

19
• To facilitate the manipulation and the assembly of the final parts; and To simplify the product structure,
reducing the assembly costs and other factors of this nature.

Table 1 .Cylinder block design efficiency calculated before the DFMA study

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

20
Table 2. Cylinder block design efficiency calculated after the DFMA study

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

21
Table 3. Features analyzed, its costs, the improvements proposed, and cost reductions

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

Table 3. Features analyzed, its costs, the improvements proposed, and cost reductions (continued)

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

23
CONCLUSION:

The results show as impact in the cost reduction of the subsystem chosen of
1.8% and in the entire engine of 0.7% using DFMA (Design for Manufacturing
and Assembly) method. For the application of DFMA method, the study showed
the most critical subsystem identification based on the cost impact in the entire
engine and, of this subsystem, the delimitation of the most representative
components.
Potential improvements, they are the following: to reduce tolerances of the
casting block, to remove the guides and seat of valves that are pressed and to
substitute them for machining and posterior thermal treatment, and to reduce
finishing specifications in surfaces where silica could be applied.

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

24
 REFERENCES
[1] Otto, Kevin & Wood, Kristin. (2001). Product Design: Techniques in Reverse Engineering and New Product Development.
[2]Stuart Pugh, Total Design: Integrated Methods for Successful Product Engineering, Addison Wesley 1991
[3]D. Stienstra, Introduction to Design for (Cost Effective) Assembly and Manufacturing, Rose‐ Hulman Institute of Manufacturing
[4]Prof. Inderdeep Singh, Manufacturing Guidelines for Product Design, Department of Mechanical and Industrial Engineering
[5] MICHEL KALYUN TEZERA WODAJO, Application Design for Manufacture and Assembly to Improving Product Design and Development
Performance Chenggang Yin, Shulin Hou* Department of Mechanical Design and Manufacture, College of Engineering, China Agricultural University,
Beijing, China 100083
[6]Application of a Design Method for Manufacture and Assembly Flexible Assembly Methods and their Evaluation for the Construction of Bridges
Master of Science Thesis in the Master’s Programme Design and Construction Project Management
[7] Design for Manufacturing & Assembly (DFMA) Tips ( EML2322L / EML4501 / EML4502 HD Version )
[8] https://web.iitd.ac.in/~hirani/lecture-mcl211-part3.pdf

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

25
THANK YOU !!!

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

26