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Lecture 08 Design For X (DFX)

The document discusses various Design for X (DFX) concepts including Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Manufacturability and Assembly (DFMA). DFX aims to optimize the product realization lifecycle by addressing issues related to manufacturing, cost, quality, assembly and serviceability at the design stage. Some key guidelines discussed include minimizing part count, using self-locating and self-fastening features, and designing for ease of part retrieval, handling and insertion.

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358 views22 pages

Lecture 08 Design For X (DFX)

The document discusses various Design for X (DFX) concepts including Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Manufacturability and Assembly (DFMA). DFX aims to optimize the product realization lifecycle by addressing issues related to manufacturing, cost, quality, assembly and serviceability at the design stage. Some key guidelines discussed include minimizing part count, using self-locating and self-fastening features, and designing for ease of part retrieval, handling and insertion.

Uploaded by

chitra2010
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Lesson 08

Operations Management
Design for X (DFX)
Dr. Inderdeep Singh
Department of Mechanical and Industrial Engineering

1
Design for Excellence (DFX)
• Design for Excellence or DFX is a systematic design approach that entails
wide range of guidelines and standards focused on optimizing the product
realization lifecycle.

• In reality, the term DFX is better thought of as Design for “X” where the
variable X is interchangeable with one of many values depending on the
particular objectives of the venture.
Design for Excellence (DFX) cont..

These guideline ensures the issues related to manufacturing, cost, quality,


assembly and serviceability are addressed at the design stage.

If these guidelines are not adhered during the design stage, it can lead to
engineering changes occurring at later stages of product lifecycle which are
highly expensive and can cause product delays and cost over-runs.
Some of the most common
substitutes for X includes: Design for
Assembly

Design for Design for


• Design for Manufacturing Reliability Manufacturing

(DFM)

• Design for Assembly (DFA)


Design for
Manufacturing
and Assembly DFX Design for
Production

• Design for Manufacturability


and Assembly (DFMA) Design for
Safety
Design for Cost

Design for

• Design for Production


Service
Design for Manufacturing

Definition
“DFM is the method of design for ease of manufacturing of the collection
of parts that will form the product after assembly”

“Optimization of the manufacturing process”


Design for Manufacturing cont..

• Design for manufacturing (DFM) is a development practice, emphasizing


manufacturing issues throughout the product development process.

• Successful DFM results in lower production cost without sacrificing


product quality.
Estimate the Manufacturing Costs
Equipment Information Tooling

Raw Materials

Labor Manufacturing
Finished Goods
Purchased
System
Components

Energy Supplies Services Waste

Source: Ulrich, K. & Eppinger, S. (2000). Product Design and Development. Boston, MA: Irwin McGraw-Hill.
Proposed Design

DFM Method Estimate the


Manufacutring Costs

Reduce the Costs of Reduce the Costs Reduce the Costs of


Components of Assembly Supporting Production

Consider the Impact of


DFM Decisions on
Other Factors

Recompute the
Manufacturing Costs

Good
N
enough
?
Y

Ulrich, K. & Eppinger, S. (2000). Product Design and Development. Boston,


Acceptable Design
MA: Irwin McGraw-Hill.
Example
• In a sheet-metal design, specifying hole sizes, locations, and their alignment is critical.
• It is always better to specify hole diameters that are greater than the sheet’s thickness (T).
• Spacing between holes also matters. It should be at least two times the sheet thickness
(2T), if not more.
• Distance between holes ensures strength of the metal and prevents holes from deforming
during the bending or forming processes.

Source: http://machinedesign.com/metals/following-dfm-guidelines-working-sheet-metal
Design for Assembly
(DFA)
Design for Assembly

Definition
DFA is the method of design of the product for ease of assembly.

“Optimization of the part/system assembly”


Design for Assembly cont..

• DFA is a tool used to assist the design teams in the design of products that
will transition to production at a minimum cost, focusing on the number of
parts, handling and ease of assembly.

.
Design for Assembly Principles
• Minimize part count
• Design parts with self-locating features
• Design parts with self-fastening features
• Minimize reorientation of parts during assembly
• Design parts for retrieval, handling, & insertion
• Emphasize ‘Top-Down’ assemblies
• Standardize parts…minimum use of fasteners.
• Encourage modular design
• Design for a base part to locate other components
• Design for component symmetry for insertion
Example

• Original design for a thermal


gunsight reticle in a US tank,
made by Texas Instruments,
Inc.

• There are a large number of


fasteners.

Source: Boothroyd, Dewhurst and Knight (1994)


• Redesigned thermal gunsight reticle:
simpler to assemble, and less to go
wrong!

Source: Boothroyd, Dewhurst and Knight (1994)


Measuring Improvement

Original Redesign Improvement

Assembly time (h) 2.15 0.33 84.7%

Number of
different parts 24 8 66.7%

Total number of parts 47 12 74.5%

Total number of operations 58 13 77.6%

Metal fabrication
time (h) 12.63 3.65 71.1%

Weight (lb) 0.48 0.26 45.8%


DFMA (Design for Manufacturing and Assembly)
What is DFMA
• DFMA is a DESIGN REVIEW METHOD

It identifies:

-OPTIMAL PART DESIGN


-MATERIAL CHOICE
-ASSEMBLY AND FABRICATION OPERATIONS TO PRODUCE AN
EFFICIENT AND COST EFFECTIVE PRODUCT

• It reveals that initial ideas may not be the most effective.

18
DFMA Guidelines

• Design guidelines are qualitative


description of good design
practices.

• Design guidelines are intended


to be used by designer during
design synthesis.

19
DFMA Guidelines

According to Boothroyd & Dewhurst ideal characteristic of part assembly


are:-
• Part is inserted from top of the assembly so that gravity helps to stabilize
the partial assembly.
• Parts and assembly site can be designed to be self aligning. The chamfer
is most common self alignment feature.
• Parts are assembled in one single linear motion.
• Parts are secured immediately after insertion
DFMA Guidelines (Example)

21
Thank you

22

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