Академический Документы
Профессиональный Документы
Культура Документы
Prepared By A.S.Deshmukh
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFM Design for Assembly A process for improving product design for easy and low-cost assembly, focusing on functionality and on assemblability concurrently."
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Assembly Methods
1. 2. 3. Manual Assembly Fixed automatic Assembly Flexible automatic Assembly
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Manual Assembly
Parts are transferred to workbenches where workers manually assemble the product or components of a product. Hand tools are generally used to aid the workers. Most flexible and adaptable of assembly methods, there is usually an upper limit to the production volume, and costs (including benefits, cases of workers compensation due to injury, overhead for maintaining a clean, healthy environment, etc.) are higher.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
1. Eliminate the need for workers to make decisions or adjustments. 2. Ensure accessibility and visibility. 3. Eliminate the need for assembly tools and gauges. (i.e. prefer self-locating parts). 4. Reduce the number of different parts - use "standard" parts. 5. Minimize the number of parts. 6. Avoid or minimize part orientation during assembly (i.e. prefer symmetrical parts). Prefer easily handled parts.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Design Guidelines for Fixed automatic Assembly Reduce the number of different components by considering does the part move relative to other parts? Use self-aligning and self-locating features, avoid screws/bolts up to maximum extend. 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 parts that require orientation. Use parts that can be feed automatically.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
How much do engineering changes cost after the design has been launched?
10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Design Test Tool Build Prod
Cost
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Basic DFA Principles of Good Design 1. Design for minimum number of parts
Is there a way that reduces the number of required parts? Are all components essential or can their functions be achieved by modifying an existing component? Can components be combined into one and manufactured as an integral multifunctional component? Less parts implies less purchases, inventory, handling, processing time, development time, equipment, engineering time, assembly difficulty, service inspection, testing, etc.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Examples
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Example-1
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Example 2
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Example-2
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Example-2
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
DFA Example-2
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Example-3
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Example-3
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
End of session-1
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
1. Specification 2. Design 3. Functional analysis (this is the first Lucas analysis) Possibly loop back to step 2 if the analysis yields problems 4. Feeding analysis (this is the second Lucas analysis) 5. Fitting analysis (this is the third Lucas analysis) 6. Assessment Possibly return to step 2 if the analyses identify problems
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Functional Analysis
In this analysis, the components of the product are reviewed only for their function. The components are divided into two groups. 1. Group A:Parts that belong to this Group are those which are deemed to be essential to the product's function. 2. Group B:Parts that belong to this Group are those which are not essential to the product's function. Group B functions include fastening, locating, etc. The functional efficiency of the design cal be calculated as: Ed = A/(A+B) x 100% where A= Number of essential components B= Number of non-essential components. Note that the design efficiency is used to pre-screen a design alternative before more time is spent on it. This analysis is intended to reduce the part count in the product. Typically, a design efficiency of 60% is targeted for initial designs.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Feeding Analysis
In the feeding analysis, the problems associated with the handling of the part are scored using an appropriate table. For each part, the individual feeding index is scored. Generally, the target index for a part is 1.5. If the index is greater than 1.5, the part should be considered for redesign. Overall, all of the product's components should meet a "feeding ratio" defined as: Feeding Ratio = (Total Feeding Index) / (Number of Essential Components) where the total feeding index is the sum of all the indices of all the parts. The number of essential components is the value A from the functional analysis. An ideal feeding ratio is generally taken to be 2.5.
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
Fitting Analysis The fitting analysis is calculated similarly to the feeding analysis. Again, a fitting index of 1.5 is a goal value for each assembly and overall fitting ration of 2.5 is desired. Fitting Ratio = (Total Fitting Index) / (Number of Essential Components)
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,
REFERENCES:
DFM/DFA Tool Kit (Appendix A) Tucson SFC Program Management Procedure (TU-PGM-18-001) Seat Engineering DFA (DENG-04-025) Weight Reporting Procedure (DENG-04-019)
e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,