PENSONIC BLENDER

DFMA ANALYSIS
PREPARED BY:
NUR KAMIL ADLI BIN MOHD NAWAR

CD100299

MOHD NOORSYAKIR BIN SAIPOL YAZAN

CD100028

KAMSIAH BINTI MUHAMMAD NAIM

CD100178

JOHAN BIN JAAFAR ZABRI

CD100247

LING HOW HUA

CD100***

MUHAMMAD FAIZAL BIN MUHAMMAD RAMLI

CD100***

GROUP 1
DFMA
MR.AZLI

1.0 INTRODUCTION

Primarily, design for assembly (DFA) is the methods for part design evaluation and also
the overall assembly design evaluation. Such methods are actually a wonderful and
effective way to identify redundant parts in an assembly and also to determine the total
assembly time and costs. Engineers are often given the task to reduce manufacturing
costs and time, especially the product design engineer, and by using the DFA software,
the engineer may assess the cost of each part that contributes to the total assembly cost,
and then simplify the product concept through the strategies in regards to the reduction of
parts of the assembly.
Usually, the strategies in regards to the reduction of parts of the assembly involve
incorporating as many features and specifications into one part as are economically
feasible and sensible. With the help of DFA software, the outcome of the product design
is a simpler but fully functional design that consists of fewer parts that is easy to
assemble.
The benefits of DFA-based product design are reduced assembly part costs, improved
quality and reliability and shorter development time. DFA software is able to help
engineers estimate the difficulty of the assembly process, make the decision making
process easier, provide a benchmark for the existing product, add focus to product design
reviews, sharpen design skills and integrate both design and manufacturing process.
Design for manufacture (DFM) on the other hand, enables engineers to forecast the
manufacturing costs of the product assembly at a very early stage, which is in the design
process. However, it should be noted that the forecast is not so accurate because the
geometries available on the DFM software, which is the DFM Concurrent Costing, are
very rough. Even so, the DFM inspires and encourages the engineers to find out
additional alternative processes and materials to produce the product assembly with more
economical value.
This is because the DFM software provides manufacturing information and knowledge
into the analysis of the cost reduction generated by the DFA. The DFM software

generates the estimation for both piece part costs and tooling investments without relying
on the historical data; hence, allowing engineers to both generate cost estimates for new
designs and explore alternative materials and manufacturing processes.
The benefits of using DFM Concurrent Costing software includes being able to estimate
costs, useful in aiding concurrent engineering and vendor-negotiating, useful as a design
tool and a competitive benchmarking tool.

1.1 Background of Problem

The task given is to redesign a product so that the cost and time for the production of the
product can be lowered maximally. The product chosen is:
Products Name : PENSONIC Blender
Model : PB-328
Date of Manufactured : 2002
Established : 1965
Products Range : Electric appliance (hair dryer, toaster, fan, vacuum, microwave and etc.)
Product Specifications:
1. 250W
2. 1-Speed
3. Powerfull Motor
4. Safety Switch
5. Mill Attachment
Parts quantity : 10 parts

1.2 Objective of Study

1. Disassemble the blender into singular parts for evaluation.

2. Evaluate the assembly efficiency of the original product by using manual Boothroyd
Dwehurst evaluation worksheet.
3. Evaluate the assembly efficiency of the redesigned product by using manual
Boothroyd Dwehurst evaluation worksheet
4. Compare the assembly efficiency of original and redesigned product in terms of
assembly time and assembly cost.

1.3 Scope of study

The scope of this study includes:

1. Only the bottom part of the blender is evaluated.

2. The software used for evaluation of the original product and the redesigned
product is only the DFM and DFA software provided by the university.
3. Redesigned product in this study is only theoretical, and no prototype will be
produced for this study.

1.4 Expected findings

The expected findings of this study include the application of DFMA which is very wide,
consisting of all type of product that the consumer requires. All products that need to be
designed, and then manufactured, can actually use DFMA methods to increase products
ability to rake in income. One of the examples is laptop production. A top Asian
electronic device manufacturer (EDM) tried to reduce the manufacturing cost of their
laptop by at least 30% within 6 months by looking for a systematic methodology to

improve overall performance. The old method used was Six Sigma method, but the new
method is to reduce the part count and assembly time of the laptop with DFMA.
The results:
Old

New

Design

Design

124

79

36.3%

708

18.6%

91

41.3%

474

36.7%

62

57.5%

549

43.8%

Difference

Laptop
Parts

Assembly Time (seconds) 870

LCD TV
Parts

155

Assembly Time (seconds) 749

Server
Parts

146

Assembly Time (seconds) 977

As such, the expected finding for this study is that the amount of parts of the blender and
the time to assemble it are significantly reduced for more efficient production.
References:
1. http://www.dfma.com/software/dfm.htm
2. http://www.dfma.com/software/dfa.htm
3. http://www.dfma.com/news/motorola.htm

2.0

LITERATURE REVIEW

2.1

Product Development
Product

Development

is

the

creation

of

products with

new

or

different characteristics that offer new or additional benefits to the customer. Product
development may involve modification of an existing product or its presentation, or
formulation

of

an

entirely new

product that

satisfies

newly

defined

customer want or market needs.

Developing new products or modifying existing products so they appear new, and
offering those products to current or new markets is the definition of product
development strategy. There is nothing simple about the process. It requires keen
attention to competitors and customer needs now and in the future, the ability to finance
prototypes and manufacturing processes, and a creative marketing and communications
plan. There are several subsets of product development strategy.
This strategy is employed when a company's existing market is saturated, and
revenues and profits are stagnant or falling. There is little or no opportunity for growth. A
product development diversification strategy takes a company outside its existing
business and a new product is developed for a new market. An example of this strategy is
a company that has sold insurance products and decides to develop a financial education
program aimed at college students. The new product is not revolutionary as there are
other companies producing similar products, but it is new to the company producing it.
Product modification strategies are generally aimed at existing markets, although
a side benefit may be the capturing of new users for the new product. An example of this
strategy is toothpaste. Toothpastes that promote whitening ability or anti-cavity attributes
are built on existing plain toothpastes that only promise clean teeth. Revolutionary
products are those for which there was no real prior need. Computers and cell phones are
good examples. Before these products appeared on the market, consumers did not know
they needed them. But, the germ of an idea on how to better communicate resulted in
products that have changed the world and have drastically changed the competitive
landscape.

Whatever strategy is employed, the new product development process must be

carefully thought through. It also requires a series of benchmarks along the way. These
evaluate whether the process should be continued as new product development is usually
expensive and time consuming. For example, if a company is in the process of
developing a new product and a competitor beats that company to market with a similar
new product, the company must make a "go/no go" decision about its own product
development options.
Whatever product development strategy a company selects, consumers need to be
front and center and involved in the process from start to finish. Set aside enough budget
for consumer evaluation of the new product at the concept, prototype and the final
product stage. Make sure you not only include those consumers who represent your
primary market, but also those to whom your company might appeal to secondarily.

Product Development Process

Product development is a broad field of endeavor dealing with the design,
creation, and marketing of new products. Sometimes referred to as new product
development (NPD), the discipline is focused on developing systematic methods for
guiding all the processes involved in getting a new product to market.
There are a number of organizations dedicated to supporting product development
professionals, such as the Product Development and Management Association (PDMA)

and the Product Development Institute (PDI). According to the PDMA, the organization's
mission is "to improve the effectiveness of people engaged in developing and managing
new products - both new manufactured goods and new services. This mission includes
facilitating the generation of new information, helping convert this information into
knowledge which is in a usable format, and making this new knowledge broadly
available to those who might benefit from it."
2.1

Consideration on Design for Assembly

Design for assembly (DFA) is a process by which products are designed with ease

of assembly in mind. If a product contains fewer parts it will take less time to assemble,
thereby reducing assembly costs. In addition, if the parts are provided with features
which make it easier to grasp, move, orient and insert them, this will also reduce
assembly time and assembly costs. 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. This is
usually where the major cost benefits of the application of design for assembly occur.
Recognizing that the most important factor in reducing assembly costs was the
minimization of the number of separate parts in a product, he introduced three simple
criteria which could be used to determine theoretically whether any of the parts in the
product could be eliminated or combined with other parts. These criteria, together with
tables relating assembly time to various design factors influencing part grasping,
orientation and insertion, could be used to estimate total assembly time and to rate the
quality of a product design from an assembly viewpoint. For automatic assembly, tables
of factors could be used to estimate the cost of automatic feeding and orienting and
automatic insertion of the parts on an assembly machine.
Design for Assembly (DFA) is an approach to reduce the cost and time assembly
by simplifying the product and process through such means as:

reducing the number of parts

combining two or more parts into one

reducing or eliminating adjustments

simplifying assembly operations

designing for parts handling

selecting fastener for ease of assembly

minimizing parts tangling

During the feasibility study, plausible solutions are explored, and rough checks
are on performance and product costs. Performance specifications for the most promising
ideas are quantified during the preliminary phase. The detail design results in the piecepart and assembly drawing design. Design for assembly (DFA) should be considered at
all stages of the design process. Concepts analyzed again cost and performance. A
systematic analysis of product assemblability performed. If cost and performance
analyses require a concept to be redefined, the efficiency of assembly - analyzed before
final approval.
The process of manual assembly is divided into two separates areas:

Handling - acquiring, orienting and moving

Insertion and fastening - mating apart to another part or group parts

Parts of assemble which required to reduce

Assembly methods can be divided into three major groups.
In 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. Although this is the most flexible and adaptable of assembly
methods, there is usually an upper limit to the production volume, and labour costs

(including benefits, cases of workers compensation due to injury, overhead for

maintaining a clean, healthy environment, etc.) are higher.
Fixed or hard automation is characterised by custom-built machiner that
assembles one and only one specific product. Obviously, this type of machinery requires
a large capital investment. As production volume increases, the fraction of the capital
investment compared to the total manufacturing cost decreases. Indexing tables, parts
feeders, and automatic controls typify this inherently rigid assembly method. Sometimes,
this kind of assembly is called "Detroit-type" assembly.
Soft automation or robotic assembly incorporates the use of robotic assembly
systems. This can take the form of a single robot, or a multi-station robotic assembly cell
with all activities simultaneously controlled and coordinated by a PLC or computer.
Although this type of assembly method can also have large capital costs, its flexbility
often helps offset the expense across many different products.
Graphically, the cost of different assembly methods can be displayed as in Figure
1. The non-linear cost for robotic assembly reflects the non-linear costs of robots (even
small ones cost alot).

Figure 1: Relative costs of different assembly methods by type and production volume.

The appropriate ranges for each type of assembly method are shown
(approximately) in Figure 2.

Figure 2: Production ranges for each type of assembly method

Assembly methods should be chosen to prevent bottlenecks in the process, as well as

lower costs.

2.3

Advantages of Design Manual Assembly and Manufacturing

The aim of design for assembly (DFA) 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.

DFA recognises the need to analyse both the part design and the whole product
for any assembly problems early in the design process. We may define DFA as "a
process for improving product design for easy and low-cost assembly, focusing on
functionality and on assemblability concurrently."
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.
Typical results of DFMA application shown will decreasimg in:

parts count

parts cost

time to market

assembly time

manufacturing assembly time

assembly operations

separate fasteners

assembly defects

service call

improvement in quality and reliability

Other than that, DFMA will:

Shorter developmental schedules and reduced cycle times.

Better first article quality

Development of robust product designs

Easier transition of designs to production

Better supplier product integration

More effective risk management

3.0

METHODOLOGY

Basically the analysis will be done in five stages :

1.

Disassemble the product and classification of each part

The selected blender will be disassemble into single part so that measurement
of each part can be done such as defining the part dimension. Shape of each part
also can determine. We can determine roughly which parts that are not needed.

2.

Assembly process evaluation ( Boothroyd Dwehurst Method )

A Boothroyd Dwehurst manual evaluation worksheet will be used to do the

evaluation of each part in term of the part handling and part insertion difficulties.
Two digits code will be given to aid the evaluation process by bringing different
consumption of assembly time.

3.

Proposed part modification and description

Identifying potential parts to simplify, eliminate, merge, redesign and etc. when
the manual evaluation have been done. When proposed the modification of part,
the value of theoretical minimum part estimation needed to be considered to avoid
the part functionless issue.

4.

Reevaluation of modified parts ( Boothroyd Dwehurst Method )

By using the same evaluation method ( Boothroyd Dwehurst Evaluation

Worksheet ), recalculate and reevaluate the efficiency of the proposed parts
modification.

5.

Comparison result of original and modified parts

Compare the result of original product and modified product in term of total parts,
assembly time, assembly cost, and assembly efficiency.

3.1

Blender assembly process

Design concept

DFA

Suggestion for simplification of

product structure

Selection of
materials and
processes and
early cost
estimates

Suggestions for more economic

materials, processes and
environmentally friendly materials

Best design
concept

DFM
Detail design for minimum
manufacturing costs
Prototype
Production

Fig. 3.1 Flow chart for typical steps taken using DFMA techniques

Introduction
of DFA and
product

Literature
review

Methodology

Boothroyd
Dewhurst
Analysis

Redesign

design

1. Defining
potential part
to be
modified.
2. Modifying
the selected
1. Disassemble

Defining the
objective and
understanding
the
methodology
of DFA

Searching for
related

eliminate,

from the

merge,

blender.
2. Categorizing

information,

part into each

benchmark,

category.

and latest

3. Measurement

design of

of each part.

product

part by

all the parts

redesign and

1. Doing

etc.

evaluation of
each part.

3. Doing

2. Calculate the

evaluation

design

again and

efficiency.

comparing

4. Comparison.

Fig. 3.1 Flow chart of blender assembly process

the result.

4.0 PRODUCT ANALYSIS

4.1 Product Detail And Specification

Products Name

: PENSONIC Blender

Model

: PB-328

Date of Manufactured : 2002

Established

: 1965

Products Range

: Electric appliance (hair dryer, toaster, fan, vacuum, microwave

and etc.)

Product Specifications:
1.
2.
3.
4.
5.
Parts quantity

250W
1-Speed
Powerfull Motor
Safety Switch
Mill Attachment
: 10 parts

4.2 Detail Drawing For Pensonic Blender Motor

Labelled parts :
1.
2.
3.
4.
5.

1 - Base Housing
2 - Top Housing
3 - Cantering Pad
5 - Foot
9 - Motor

Unlabelled parts :
1.
2.
3.
4.
5.

4 - Motor Pad
6 - Switch
7 - M3 Plain Washer
8 - M6 Base Screw
10 - Wire Cord

30

1.95

29

3.00

4.95

0.05

Base Housing

30

1.95

29

3.00

4.95

0.05

Top Housing

30

1.95

27

3.00

4.95

0.05

Centering Pad

30

1.80

27

3.30

5.10

0.05

Motor Pad

30

5.60

29

6.50

24.20

0.24

Foot

30

1.95

97

3.30

5.25

0.05

Switch

11

1.69

39

3.00

28.14

0.28

M3 Plain Washer

11

1.50

39

9.60

58.40

0.57

M6 Base Screw

3.00

30

3.80

6.80

0.07

Motor

10

30
00

5.60

29

8.90

14.50

0.14

Wiring Cord

Number of times the

operation is carried
out consecutively

Part I.D Number

Operation cost (RM)

Figure for theoretical

minimum part estimation

Operation time (sec)

Manual insertion per

time per part

Two-manual
insertion code

Manual handling
time per part

Two-digit manual
handling code

4.3 Evaluation of Pensonic Blender

1
2
3
4

Name of
Assembly

TM

CM =
NM =

Total manual assembly

time
Total cost of manual
assembly
Theoretical minimum number of
parts

Design Efficiency
157.24

1.55

= (3*NM)/TM
= (3*8)/157.24

TM

CM

NM

= 0.15 @ 15%

4.4 Evaluation of Total Design Pensonic Blender using DFA and DFM software

For this evaluation, please refer appendix because DFMA analysis were done
for every part.

4.5 Example of Handling Code and Insertion Code Calculation

Part ID: Base Housing

Dimension: 19mm x 152mm

4mm

Quantity: 1

360
360

(+) = 720

the part is easy to grasp and manipulate

the thickness is larger than 5mm

Therefore the handling code is 30, estimated time is 1.95s

Manual insertion:
this part is secured immediately
there have screwing operation or plastic deformation immediately after
insertion
it is easy to align and positioning
Therefore the insertion code is 29, estimated time is 3s

Total time = 1.95s + 3s = 4.95s

Total cost = 1 x 4.95 x 0.0104 = RM0.0515
The figure for theoretical minimum part estimation = 0
Part ID: Base Screw

Dimension: M6 x 15mm
Quantity: 2

360
0

Manual Handling:
(+) = 360 < 540
the part is easy to grasp and manipulate
the thickness is larger than 2mm
the size of screw is larger than 6mm but smaller than 20mm
Therefore the handling code is 11, estimated time is 1.5sec
Manual insertion:
this parts is considered as added but not secured
there have screwing operation or plastic deformation immediately after
insertion
it is easy to align and positioning
resistance to insertion

Therefore the insertion code is 39, estimated time is 9.6sec

Total time = 1.5s + 9.6s = 11.1sec
Total cost = 2 x 11.1 x 0.0104 = RM0.2309
The figure for theoretical minimum part estimation = 0

4.6 Proposed Modifications

Original Design
1) Blade

Modified Design (Proposed Idea)

1) Blade

Description :
Original design of this blender used the screw thread concept and the motor will be
attached along with the drive socket. The problem is the screw thread is unnecessary so it
can be replace by the self-align concept. Furthermore, the size of socket drive has been
reducing so the size and width can be reducing. The new design as shown in figure
above, the screw has removable and the blade will be fit and easy to use it.

Assembly Time : 3.9s

Percentage of reduction : 61.54%

Assembly Time :1.5s

2) Motor

2) Motor

Description :
Original design of this blender used the screw thread concept and the motor will be
attached along with the drive socket. The problem is the screw thread is unnecessary so it
can be replace by the self-align concept. The new design as shown in figure above, the
screw has removable and the blade will be fit and easy to use it.
Assembly Time: 5.78s

Assembly Time: 5.8s

Percentage of reduction : 0
3) Base Housing

3) Base Housing

Description :
Original design of this blender lower case is square shape and used concept screw to fit
the blender upper case. The problem is time consume to assembly the blender body due
to its shape and assembly method. With the new design, the lower case has been shape to
a circular shape and the screw has been eliminated. The new method of securing the
lower case its by tapping method.

Assembly Time: 30.59s

Assembly Time: 2.7s

Percentage of reduction: 90.91 %

4) Body

4) Body

Description :
Original design of this blender upper case is square shape and used concept screw to fit
the blender upper case. The problem is time consume to assembly the blender body due
to its shape and assembly method. With the new design, the overall shapes are much
simplified and ergonomic.

Assembly Time: 4.67s

Assembly Time: 2.5s

Percentage of reduction: 46.47%

5) Switch

5) Switch

Description :
Original design of this switches blender is common size and probably can be change to a
new one. Further the operation of the switch is manually operation. With the new design
of the switch the size has been reduce and the operation method is changed to semiautomatic operation.
Assembly Time: 2.59s

Assembly Time: 1.7s

Percentage of reduction: 34.36%

6) Screw

6) Screw

Description:
The original screw is without a washer and with a new design and what is available in the
market, chooses the screw that attached with washer so the assembly time can be reduce
along with number of part.
Assembly Time: 1.05s
Percentage of reduction: 0 %

Assembly Time: 1.05s

4.7 Exploded view of the Assembly Redesign Pensonic Blander

1
3

4
1

6
8
1

Improved Blender Design

Part No.
1
2
3
4
5
6
7
8

Part Description
Blade
Body
Switch
Motor
Self-Tapping Screw
Wiring Cod
Base Housing
Foot
Table: Bill of Material

4.8 Evaluation of Total New Design Pensonic Blender using DFA and DFM
software

For this evaluation, please refer appendix because DFMA analysis were done
for every part.

4.9 Example of Handling Code and Insertion Code Calculation

Part ID: Base Housing

Dimension: 130mm (diameter) x

12mm (h)
Quantity: 1

360
360

(+) = 720

the part is easy to grasp and manipulate

the thickness is larger than 15mm

Manual insertion:
this part is secured immediately
there have screwing operation or plastic deformation immediately after
insertion
it is easy to align and positioning

Part ID: Base Screw

Dimension:
Quantity: 2

360
0

Manual Handling:
(+) = 360 < 540
the part is easy to grasp and manipulate
the thickness is larger than 2mm

the size of screw is larger than 6mm but smaller than 15mm
Manual insertion:
this parts is considered as added but not secured
there have screwing operation or plastic deformation immediately after
insertion
it is easy to align and positioning
resistance to insertion

5.0

DISCUSSION AND CONCLUSION

Redesign is one of the common methods of developing products in industrial world. In

order to redesign a product, there is a need to find the fallibility of current products and
obtain the design parameters. In this study the fallibility parameters of blender were
identified by Boothroyd Dewhurst Analysis Method. Therefore, the strengths and
weaknesses of each product would be identified. Below data was showing the final value
after making a redesign of product.

Table 5.1 Comparison of analysis data

Original design

Redesign

Improvement %

157.24

67.25

57.23

Number of
different part

10

20

Total number of
parts

20

10

50

1068.37

1861.64

-42.6

9.3

8.7

Total assembly
time (s)

Total cost ( $ )
DFA Index

Base to the software, its mentioned that a good design improvement must be more
consider to the simplifying the design with change the functionality of the original part.
Therefore, the existing blender consists of 8 total parts needed to assemble together to
become a complete product. From the data obtained, it shows that there is a reduction in
the number of part and assembly time on the object being studied. This could increase the
production of a product and can directly increase the manufactures profit.

However for the total cost per product shows an increment up to 42%. This might
happen due to in our case study, we are not testing with other material or process to made
it so that any characteristic of product not be changed. In the industries, the practice of
the production is in mass production. Any reduction on number of product or parts might
not change the production cost due to its continuous and nature process of the machine.
But there is an decrement on the labor which is any part to be made and assembly need
some worker to do something on it.

Additional of the efficient in redesign product is the total assembly time. The assembly
time can be saved around 57% and this is same as 2 redesign products at 1 old product
assembly can be completed. So if the manufacturing volume around 1000 pieces per day,
with redesign it can be 2000 pieces might be completed by the labor.

OLD

NEW

Pictures