Universiti Brunei Darussalam Faculty of Integrated Technologies

TM-3303
Term Project

“Application of the principles of Product Design for Manufacturing and Assembly

for improvement of an existing design of an engineering product”

Course Instructor: Dr. Asif Iqbal (Associate Professor)

Project Scope
Project teams must thoroughly perform a study that shows a detailed comparison
between a “current design” and a proposed “redesign” of one product using the
guidelines and requirements in the concept of DfMA. The redesign must show updates
based on the DFMA criteria without impeding parts/product functionality. All steps must
be carefully documented and presented in the form of written reports and live
presentations. Data should be tabulated and organized in a professional manner.

Problem Statement
You are a part of a product development team introducing a proposal to your
corporation management for a “product redesign” to improve the design efficiency of an
already existing product. You need to defend your ideas and show strong evidence to
convince them to accept your proposal. They are eager for new ideas that will help
reduce manufacturing and assembly cost and time. You need to apply the concept
of DfMA to show your work and to quantitatively illustrate your comparison criteria.

Benefit proposition
Ease of assembly and ease of manufacture are believed to increase productivity and
reduce cost. Other benefits such as reducing assembly time are appealing factors for
the proposal acceptance. Your corporation seeks market competition and your task is to
persuade them to implement the concept of DfMA through your proposal. A redesign
that satisfies these needs can be beneficial to the corporation future.

Each student will be asked to carefully redesign a product to meet these requirements
and present a report that demonstrates key elements of the proposed redesign.

Deliverables
Project deliverables which will be assessed throughout the term: 40% of total grade

– Initial Report (Scope and Proposal) - (February 06)

– Progress Report - (March 13)
– Final Project Report- (April 17)
– Project’s Presentation- (April 17)

Initial Design Proposal (Report)

This report should clearly describe the initial idea and the expected outcomes that will
support the proposal for redesign. Justify the proposed concept in terms of how it best
satisfies needs and specifications.

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Contents must include:

 Title page
o Project title, member name, date, and the School Pledge
 Introduction
o Explain problem statement, scope of assignment, general constraints
 State-of-the-art review on related or similar case studies
o Discuss actual examples on the market and their success stories with DfMA
 Summary of the primary needs / specs driving the opportunities to redesign
 A brief overview of the original design
o Clearly indicate its function
o Create a Functional decomposition and function /structure analysis
o Include well-labeled figures to illustrate each component concept (form, function,
how)
o Label key components in these figures (with concise text and arrows)
o In a table state the original number of parts in an assembly, Theoretical part count,
assembly time and estimate total assembly cost. State the process/material
combination of each part in the original design.
o You might use the (spreadsheet) to ease and organize your table(s)

Progress Report

Contents must include:

 A brief review of initial proposal
o Reminder of problem statement, driving needs, and critical specs
o A brief review of original design and considerations about design simplifications and
expectations due to proposed changes in the redesign
o Show your work towards starting of a comparative study and your expectations
towards the applications of the DFMA concept
 A summary of the final proposed design
o Technical drawings
o Major systems/subsystems diagram
o How does this design address needs/specs?
o Changes made to enhance first assumptions in your proposal
o Identify aspects that must be evaluated to prove DFMA concept functionality

Final Presentation
A (10 mins maximum) slide presentation must be given that summarizes the final
product in detail.
The presentation will be assessed by your course instructor.

Presentation contents must include (but are not limited to):

 Introduction and problem statement
 Design overview

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o What is it? What does it do?

o Critical components of design and their function
o Why you choose such design and justification about possible improvements based
the DfMA concept
 Problems encountered, revisions made, etc.
 Analysis of redesign
o Compare original and redesign
o Quantify benefits (cost and assembly time estimate) due to application of the DfMA
 Conclusions

Final Project Report

A report must be submitted that discusses the final comparison analysis and
improvements done to redesign using the concept of DFMA. A thorough discussion
must be included explaining how the project was carried out and how well the
establishment goals were met.
Each student has the freedom to include additional sections/information not specified
below, but the following must be included:

 Title Page
o Project title, member’s names, date, and the School Pledge
 Table of Contents
 Introduction
o Explain problem statement, scope of assignment, general constraints, and proposed
solution
 State-of-the-Art Review
 Original Design Overview
o Structure & Function
o Assembly time estimates
o Manufacturing cost estimates
o Design efficiency Index
 Redesign Overview
o Part count after redesign
o Redesign Structural/functional analysis
o Decision- Making and justification about redesign choices
 Production Plan
o Manufacturing plan, cost estimate, production volume, etc. for redesigned
(consolidated parts)
 Engineering Analysis
o Data acquisition and data analysis
o Comparison strategy and criteria for electing redesign over old design
o Modeling & Simulations of new components designed based the DFMA

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 Trials and Errors

o Discuss your trails and errors until reached a final decision on your product redesign
 Design Evaluation
o Describe the success of your redesign in meeting specs/needs/etc.
 Lessons Learned
o What did you learn throughout the course of the project?
o What difficulties did your project encounter? And what was your approach to
overcome such difficulties?
o What would you do different if the project was being started over?

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