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Design For Assembly: DFXPLCM

This document discusses design for manufacturing (DFM) and design for assembly (DFA). DFM aims to reduce manufacturing costs by simplifying the manufacturing process, while DFA aims to reduce assembly costs by simplifying the assembly process. There is sometimes a tradeoff between DFM and DFA, which is addressed by design for manufacturing and assembly (DFMA). The document outlines principles and guidelines for both DFM and DFA, including minimizing parts and operations. It also discusses different assembly methods like manual, fixed automation, and robotic assembly, and their relative costs. Design guidelines are provided for different assembly contexts. Metrics like assembly time, efficiency, and part count are discussed for evaluating assembly design.

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49 views37 pages

Design For Assembly: DFXPLCM

This document discusses design for manufacturing (DFM) and design for assembly (DFA). DFM aims to reduce manufacturing costs by simplifying the manufacturing process, while DFA aims to reduce assembly costs by simplifying the assembly process. There is sometimes a tradeoff between DFM and DFA, which is addressed by design for manufacturing and assembly (DFMA). The document outlines principles and guidelines for both DFM and DFA, including minimizing parts and operations. It also discusses different assembly methods like manual, fixed automation, and robotic assembly, and their relative costs. Design guidelines are provided for different assembly contexts. Metrics like assembly time, efficiency, and part count are discussed for evaluating assembly design.

Uploaded by

giriaj kokare
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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DESIGN FOR

ASSEMBLY
Prof. G M Gambhire

DFXPLCM
DFM AND DFA
 Design for Manufacturing (DFM)
 Concerned with reducing overall part production cost
◼ Minimize complexity of manufacturing
◼ Use common axes and common processes

 Design for Assembly (DFA)


 Concerned with reducing product assembly cost
◼ Minimize number and complexity of assembly operations
◼ Individual parts may be more complex in design

 Trade-off between DFM and DFA ===> DFMA


DFXPLCM
PRINCIPLES OF DFM (DFM GUIDELINES)

▪Simplify and reduce the number of manufacturing operations


▪Standardize materials and use common parts
▪Design for efficient joining
▪Open tolerance as much as possible
▪Allow over-travel in part design
▪Avoid special tooling and frequent tool changes
▪Select materials for best manufacturability
▪Specify ‘acceptable’ surface finish for functionality
▪Machine for one primary axis whenever possible
DFXPLCM
PRINCIPLES OF DFA (GUIDELINES FOR ASSEMBLY)

▪Minimize part count


▪Design parts with self-locating features
▪Design parts with self-fastening features
▪Minimize reorientation of parts during assembly
▪Emphasize ‘top-down’ assemblies
▪Standardize parts
▪Encourage modular design

DFXPLCM
ASSEMBLY METHODS

Manual – parts are transferred to workbenches where workers manually


assemble the product or components of a product. – Hand tools generally used

Fixed or Hard Automation – characterized by custom-built machinery that


assembles one and only one specific product

Self Automation or Robotic Assembly – incorporates the use of robotic


assembly systems. – single robot or multi-station robotic assembly cell with all
activities simultaneously controlled and coordinated by a PLC or computer

DFXPLCM
COMPARISON OF ASSEMBLY METHODS
Manual Fixed Automation Robotic Assembly
Assembly Assembly

Features Parts are Custom-built machinery Robotic assembly systems.


transferred to
workbenches
Hand tools generally
used
Flexibility, As production volume Flexibility often helps offset
Adaptability increases, the fraction of the the expense across many
capital investment different products
Advantages compared to the total
manufacturing cost Production volume
decreases maximized, more than one
products.
Upper limit on Large capital investment Largest capital investment
production volume
Disadvantages Labor costs Inherently rigid due to
(benefits, workers indexing tables, parts
comp, healthy feeders, and automatic
environment) controls
DFXPLCM
ASSEMBLY METHOD COSTS

DFXPLCM
DESIGN GUIDELINES FOR MANUAL ASSEMBLYE

▪Eliminate the need for workers to make decisions or adjustments.

▪Ensure accessibility and maximize visibility.

▪Eliminate the need for assembly tools and gauges (i.e. prefer self-locating
parts).

▪Minimize the number of custom parts - use "standard" parts.

▪Minimize the number of parts.

▪Avoid or minimize part orientation during assembly (i.e. prefer symmetrical


parts).

▪Prefer easily handled parts that do not tangle or nest within one another.
DFXPLCM
DESIGN GUIDELINES FOR ASSEMBLY

▪Reduce the number of different components by considering


▪ –does the part move relative to other parts?
▪ –Must the part be of a different material or isolated from other parts (electrical, vibration, etc.)?
▪ –Must the part be separate to allow assembly (cover plates, etc.)?

▪Use self-aligning and self-locating features


▪Avoid screws/bolts where possible, why?
▪Use the largest and most rigid part as the assembly base and fixture. Assembly
should be performed in A layered, bottom-up manner.
▪Use standard components and materials.
▪Avoid tangling or nesting parts.
▪Avoid flexible and fragile parts.
▪Avoid parts that require orientation, why?
▪Use parts that can be fed automatically.
▪Design parts with a low centre of gravity. DFXPLCM
SYMMETRY

Illustration of principle: Which part can be ‘aligned’ with minimum rotation?


How many axes of symmetry?
EML4550 2007 DFXPLCM
SELF-LOCATING PARTS

EML4550 2007 DFXPLCM


SELF-LOCATING PARTS

EML4550 2007 DFXPLCM


TOP-DOWN ASSEMBLY

EML4550 2007 DFXPLCM


FASTENING

Consider the least expensive fastening method that meets the requirements

EML4550 2007 DFXPLCM


LESS PARTS

DFXPLCM
DESIGN EFFICIENCY

A quantitative measure of time and cost required to assemble a


product

A rating which can be used to judge the effectiveness of a current


design (a benchmark for future improvements)

Design efficiency is the end result measure as calculated by the


Boothroyd-Dewhurst process
 Symmetry of parts (repeatability for orientation)
 Size and thickness
 Handling time
 Insertion time Boothroyd & Dewhurst complexity factor

EML4550 2007 DFXPLCM


HANDLING
Handling difficulty
Handling Time
Size
How many hands required?
Thickness
Any grasping assistance needed?
Weight
Effect of part symmetry on assembly
Fragility
Is part easy to align/position?
Flexibility
Slipperiness
Insertion time
Stickiness
Is part self-securing?
Necessity for using:
Need to hold down?
 Both hands
What fastening process?  Optical magnification
Easy to2007
EML4550 align/position?  Mechanical assistance DFXPLCM
EML4550 2007 DFXPLCM
BDI CRITERIA FOR PART MINIMIZATION
(COLUMN 9)

If the answer to ALL THREE of these questions is NO, then the part is a
candidate for elimination (“0” in column 9)

 During operation of the product does the part move relative to all other parts
already assembled? Only gross motion should be considered (small motions
that can be accommodated by elastic hinges, for instance, should not count as
positive answer)

 Must the part be of a different material than all other parts already
assembled? Only fundamental reasons concerned with material properties
are acceptable

 Must the part be separate from all other parts already assembled because
otherwise necessary assembly or disassembly of other separate parts would
be impossible?
EML4550 2007 DFXPLCM
BDI EXAMPLE

EML4550 2007 DFXPLCM


DFXPLCM
DFXPLCM
DFXPLCM
DFXPLCM
DFXPLCM
DFXPLCM
DFA PROCESS

DFXPLCM
DFA ANALYSIS WORKSHEET

DFXPLCM
DFA COMPLEXITY
Count Parts & Interfaces

 List number of parts (Np)


 TH Count part Efficiency

 List number of interfaces (Ni)


 Complexity Factor

DFXPLCM
CONSIDERATIONS/ASSUMPTIONS

The first part is essential (base part)

Non-essential parts:
– Fasteners
– Spacers, washers, O-rings
– Connectors, leads

Do not include liquids as parts (e.g.. glue, gasket sealant, lube)

DFXPLCM
FUNCTIONAL ANALYSIS

DFXPLCM
FUNCTIONAL ANALYSIS

Divided into groups A (essential for product function) and


B (not essential for product function)

Design efficiency,
De = A/(A+B) x 100%

DFXPLCM
HANDLING

DFXPLCM
MCDONNEL DOUGLAS EXPERIENCE
➢Reduce number of parts and fasteners used on aircraft

➢It means fewer opportunities for defects

➢For each fastener there is the chance that the hole will be drilled in the wrong place or be the wrong size

➢By reducing the number of fasteners – numbers of defects reduced, therefore, produce a higher quality
product

➢Weight is critical. Fuel costs approximately $50,000 per pound of aircraft weight over 6000 hrs of the life of
the aircraft

➢There are 179000 on the FA-18 CD fasteners

➢In previous models several parts were made of sheet metal because machined parts were unable to reach
minimum gage limits

➢With high speed machining – thinner gauge limits have become possible
DFXPLCM
EASE OF ASSEMBLY

DFXPLCM
NO OF PARTS REDUCTION

DFXPLCM
THANK YOU

Refer case studies shared on Google classroom.

Read DFA Measures .pdf file for “Staple Remover” DFA analysis
process.

Also, read the textbook for the matching syllabus content.

DFXPLCM

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