Dfa Final Portfolio-Ilovepdf-Compressed

18WSC400 ELECTIVE - DESIGN FOR ASSEMBLY
COURSEWORK ASSIGNMENT NO. 3

DFMA EVALUATION & REDESIGN OF A MIXER VALVE
SUBMITTED ON 13th DECEMBER 2018
B418539 - Abhi Ghavalkar (C)

B520712 - Bill Bathurst
B520877 - Josh Rice
B519767 - Max Douch
B520052 - Miranda Rupp (S)
B525185 - Philip Yeung
Executive Summary
A DFMA analysis was carried out on a shower mixer valve (Virtue ER/ERD) provided by Mira showers. The result
of the analysis was a 39.74% decrease in assembly time and a 31.36% increase in design efficiency. The product
was assessed against the DFA best practice guidelines, the Product Design Specification provided by Mira, and
by testing the assembly using 3D printed parts. The cost implications of all the decisions were analysed along
with a profit analysis. New tools required for the manufacture of the newly-designed parts were also suggested.
CONTENTS
INTRODUCTION, AIMS & OBJECTIVES
1 - ORIGINAL PRODUCT ASSESSMENT
2 - OPPORTUNITY IDENTIFICATION
3 - PROPOSAL OF ALTERNATIVES
4 - COMPARISON TO ORIGINAL
5 - FEASIBILITY ASSESSMENT
6 - PRODUCT & PROCESS CHANGES
EVALUATION AGAINST AIMS & CONCLUSION

INTRODUCTION, AIMS & OBJECTIVES
INTRODUCTION:
The product being assessed is a Mira Virtue ER/ERD Shower Mixer Valve. Mira have been designing showers for 90
years and use the highest quality materials in their products. The mixer valve blends hot and cold water to ensure
constant safe shower outlet temperature. A heritage style of design has been used in the Virtue range to fit com-
fortably in with modern and traditional bathrooms. A phone conference with Mira enhanced the group’s under-
standing of the product, manufacturing and assembly. This allowed for a comprehensive redesign of the Mira
Virtue Shower Mixer Valve.
AIM:
To redesign the Mira Virtue shower mixer valve for better assemblability, and therefore, to reduce its overall
manufac-ture and assembly costs as well as any concomitant savings that might accrue in the overheads.
OBJECTIVES:
1) Assess the product for ease of manufacture and assembly.
2) Identify opportunities for improvements in product and process design.
3) Propose alternatives for product and process design.
4) Compare the proposal to the original design.
5) Assess the technical and commercial feasibility of the proposed design.
6) Recommend resultant product, process and tooling changes.
The portfolio is structured based on the six objectives outlined above.

MIRA VIRTUE
1 - ORIGINAL
PRODUCT
ASSESSMENT
MIRA VIRTUE - ORIGINAL PRODUCT ASSESSMENT
Product and Production Process Development in Industry
Excerpts from PDS Process

1) Tactical project to introduce a heritage style mixer shower, targeted towards PDS states the marketing M(ust have), S(hould have), C(ould have) and W(on’t
consumers shopping in PurePlay channels. have) qualities.
2) Target Pure Play initially as fastest route-to-market. The design qualities are split under the headings of Aesthetics, Performance,
Design Detail, Ergonomics, Size, Material Details, Installation Maintenance, Life in
3) Capitalise on consumer readiness to adopt different aesthetic styles and Service (Operation), product Life Span, Warranty Rate %, Environment and Visual
consumer perception of 'heritage' as a more premium design. Design Intent.
4) Contribute to an improved vitality and margin for the mixer shower category. These are given a Must have quality and on some also a Won’t have quality.
Target Market It is assumed that a top-down approach has been applied.

PurePlay is a company that only focuses on one service or product.
In this, the final price (RRP =£525) is indicated at the start of the process.
Domestic UK customers are the primary target.
Once the development of the product has finished and a final manufacturing
cost is given, the profit can be calculated.
Competitors
1) Soak Traditional Thermostatic.
This is the same approach that will be undertaken when carrying out the DFMA
exercise.
2) The Bath and Co. Barrington.
The final price will remain the same and all costs that are saved on reduced part
count, manufacturing process reduction, and reduced assembly time will all
lead to increased profit margin rather than a reduced retail cost for the product.
Exploded View Showing Components in Original Mira Virtue
TOTAL NUMBER OF
O RING 55.6 X 2.4
NUMBER PARTS BEING
OF PARTS EVALUATED
51
incl. Cartridge
14
sub-assembly
CLASSIC BODY ASSY HUB
VIRTUE SHROUD
HANDLE
THERMSTREAM S8 NATURAL
LIST OF COMPONENTS M4 X 40 CAP SKT PATCHED

1 THERMSTREAM S8 NATURAL BEARING
2 CLASSIC BODY ASSY
3 HANDLE
4 HUB
BEZEL RETAINER
5 CERAMIC BEZEL
6 O RING 55.6 X 2.4 CERAMIC BEZEL
7 VIRTUE SHROUD HANDLE BOTTOM
8 BEARING
9 HANDLE WASHER
10 M4 X 40 CAP SKT PATCHED
11 BEZEL RETAINER
HANDLE WASHER
12 ADHESIVE PAD
13 BEZEL SPRING BEZEL SPRING
14 HANDLE BOTTOM
ADHESIVE PAD
Parts List with Dimensions, Symmetry and Images
Assembly CAD Diameter (mm) / Height Weight

β Length (mm)
Operation Component Count Description Image Materials α (°) α+β (°) Thickness (mm) (mm) (g)
(°) [1 dp]
Reference Number [1 dp] [1 dp] [1 dp]
Brass (Chrome-
1A 2 1 CLASSIC BODY ASSY 360 360 720 171.0 91.8 67.6 1020.0
plated)
Mixture of materials
1B 1 1 THERMSTREAM S8 NATURAL 360 360 720 50.0 98.2 N/A 141.0
in sub-assembly
1C 6 1 O RING 55.6 * 2.40 Nitrile/PTFE 180 0 180 62.0 2.3 N/A 1.0
1D 4 1 HUB Glass-filled Nylon 360 180 540 12.1 13.0 19.5 2.0
1E 8 1 BEARING Acetal 360 180 540 18.9 6.8 N/A 1.0
1F 7 1 VIRTUE SHROUD ABS (Chrome-plated) 360 360 720 65.0 35.7 N/A 18.0

β Length (mm)
(°) [1 dp]
1G 14 1 HANDLE BOTTOM Brass (Chrome-plated) 360 0 360 21.8 14.0 N/A 16.0
1H 3 1 HANDLE Zinc (Chrome-plated) 360 180 540 69.4 37.4 N/A 60.0
1I 10 1 SCREW M4 X 40SKT Stainless Steel 360 0 360 6.8 44.3 N/A 5.0
1J 9 1 WASHER Nylon 360 0 360 12.9 3.4 N/A 1.0
1K 11 1 BEZEL RETAINER Glass-filled Nylon 360 180 540 18.7 6.7 N/A 1.0
1L 13 1 BEZEL SPRING Spring Steel 180 0 180 9.1 10.4 N/A 1.0

β Length (mm)
(°) [1 dp]
1M 12 1 STICKY PAD Adhesive 0 0 0 5.6 5.6 1.2 1.0
1N 5 1 CERAMIC BEZEL Ceramic 360 360 720 20.8 9.3 N/A 4.0
1S N/A 1 POLYBAG 10 X 12 INCHES 360 0 360 ~160.0 ~240.0 N/A N/A

Cost Split for Individual Components
MIRA VIRTUE ERD Out of Total Out of 14 Parts Out of 12 Parts

0.39% ASSEMBLE & TEST MODULE (1332278) # Split % Split % Split % Component
0.65% ASSEMBLE & TEST MODULE (1332278)
1 0.1282 12.82% 0.3919 39.19% N/A N/A THERMSTREAM S8 NATURAL
8.29% 8" DELUGE SHOWERHEAD
4.96% TRADITIONAL HANDSHOWER 2 0.1528 15.28% 0.4672 46.72% N/A N/A CLASSIC BODY ASSY
3.04% HOSE 1.75M H-FLEX EN1113 3 0.0205 2.05% 0.0627 6.27% 0.4448 44.48% HANDLE
20.55% TRADITIONAL DIVERTER ASSY 14 0.0078 0.78% 0.0237 2.37% 0.1685 16.85% HANDLE BOTTOM
3.34% RISER PIPE BENT CHROME 7 0.0049 0.49% 0.0151 1.51% 0.1070 10.70% VIRTUE SHROUD
0.82% DIVERTER PIPE CHROME 5 0.0030 0.30% 0.0092 0.92% 0.0649 6.49% CERAMIC BEZEL
1.64% RISER PIPE LONG
13 0.0018 0.18% 0.0054 0.54% 0.0383 3.83% BEZEL SPRING
5.03% BRACKET CHROME
0.40% MINI PIPE CONCEALING PLATE CHROME 11 0.0014 0.14% 0.0043 0.43% 0.0308 3.08% BEZEL RETAINER
0.10% O KEY 4 0.0014 0.14% 0.0043 0.43% 0.0304 3.04% HUB
0.29% HEADNUT SOCKET 6 0.0013 0.13% 0.0041 0.41% 0.0292 2.92% O RING 55.6 X 2.40
1.16% COMPONENT PACK ERD 10 0.0013 0.13% 0.0039 0.39% 0.0279 2.79% SCREW M4 X 40 CAP SKT PATCHED
1.68% 18MM COMPRESSION NUT CHROME 8 0.0013 0.13% 0.0039 0.39% 0.0276 2.76% BEARING
0.18% OLIVE 18MM DZR BRASS
12 0.0010 0.10% 0.0032 0.32% 0.0225 2.25% STICKY PAD
0.23% IUG MIRA VIRTUE
0.04% INSTALLATION TEMPLATE 9 0.0004 0.04% 0.0011 0.11% 0.0080 0.80% HANDLE WASHER
0.01% GUARANTEE REGISTRATION CARD
0.01% POLY BAG 10" X 12" Contribu�on of parts excluding body and cartridge 14.09%
1.12% CARTON VIRTUE
1.10% INNER FITMENT
0.11% LABEL VIRTUE ERD TOP
As the manufacturing price was found to contain sensitive information, a list of parts and
0.00% LABEL BLANK PRODUCT IDEN 25x10mm tools along with their contribution towards the total manufacturing price was requested
12.82% THERMSTREAM S8 NATURAL from Mira.
0.14% HUB
15.28% CLASSIC BODY ASSY From the full list of products, the 14 parts being investigated contributed to 32.71% of the
2.05% HANDLE total cost.
0.78% HANDLE BOTTOM
0.30% CERAMIC BEZEL From these 14 parts, as the Thermstream and the Body were not being redesigned, the DFA
0.14% BEZEL RETAINER analysis was effectively taking place on 12 parts that contributed to 14.09% of the costs
0.10% STICKY PAD associated with the 14 parts.
0.18% BEZEL SPRING
0.49% VIRTUE SHROUD Neglecting the Thermstream and the Body, the parts were ordered in descending order of
0.13% BEARING their contribution to the product to determine which parts should be targeted first from a
0.13% SCREW M4 X 40 CAP SKT PATCHED
cost saving point-of-view by eliminating them.
0.04% HANDLE WASHER
0.56% 18MM COMPRESSION NUT CHROME
The results showed that the Handle Bottom (16.85%), Bezel Spring (3.83%), Bezel Retainer
0.06% OLIVE 18MM DZR BRASS
0.01% SCREW M5X6 SKT SET PCP A2
(3.08%), and Hub (3.04%)had to be considered first as they had a higher contribution to
0.13% O RING 55.6 X 2.40 the manufacturing cost and did not class as essential parts (theoretical minimum).
0.70% COMPRESSION NUT 88/415
0.06% OLIVE 15MM BRASS (DZR)
1.50% TRIM VALVE MODULE (1332278)
0.61% DIVERTER ASSY & PACK
1.94% FINAL PACK
3.22% FINAL PACK
14+1 Parts being inves�gated (incl. packaging)

Graphical Assembly Sequence
1 Load Body into fixture 4 Screw down headnut

2 Grease inside of Body 5 Shut off cartridge (Thermstream) 11 Affix date label to Shroud
10 Locate Bearing
3 Insert Thermstream into 6 Locate into fixture & test 12 Locate Shroud on to Body
Body
7 Place body into assembly fixture 9 Locate Hub
8 Locate O Ring
3
12
13 Locate Handle Bottom on 14 Push down Shroud 15 Locate Handle in to Hub

to Hub
16 Locate Washer on to Screw
17 Locate Screw+Washer in Handle
13 14 15 16 17
18 Locate Bezel Retainer in fixture

20 Remove Bezel Retainer+Bezel Spring from fixture and locate 21 Remove backing from Stick Pad; locate in recess of Bezel Retainer
22 Remove backing from Stick Pad; locate Bezel on to Pad
21 22
19
19 Insert Bezel Spring into Bezel Retainer
Standard pipe fitting operations and a post-op inspection take place after operation 22.
5 fixtures, 4 hand tools and 2 additional assembly aids are currently used in production.
Assessment of Tools, Fixtures, Jigs, Assembly Aids and Workstations
Aid Image Use

Fixture J22852 Load CLASSIC BODY ASSY
Air Driver 10.0Nm Start Headnut thread by hand and screw down to
Driver Bit J22855 correct torque
Hand tool J22847 Turn the hub fully clockwise to shutoff Cartridge
ADLT Fixture Locate assembly in ADLT fixture and test to PPTR 268
PPTR 268
Assembly Fixture J24324 Place Body assembly int assembly fixture J24324
Assembly Aid J24326 Push down on top of Shroud so that it is fully closed
Fixture J24324 Locate BEZEL RETAINER assembly and locate I fixture
HAND TOOL J24327 Using handtool insert BEZEL SPRING into Bezel Retainer
The table on the left-hand side shows the list of tools (orange), fixtures (green), and assembly aids (blue).
HAND TOOL J24325 Remove Bezel Retainer assembly from fixture and
locate into Handle assembly. Using handtool push
down and rotate 90 degs clockwise The image on the right-hand side depicts the workstation used to currently assemble the Mira Virtue mixer valve.
It is assumed that the workstation layout will not change after the redesign of the product.
Assembly Fixture 24269 Pick up Body Assembly and place in fixture

Product Design Specification
Project Summary / Objectives 2 - Design

1) Tactical project to introduce a heritage style mixer shower, targeted towards consumers 2.1 Aesthetics MUST HAVE WON'T HAVE
shopping in PurePlay channels. ER: Single mode overhead. Dual mode overhead.
2.1.1 Variants
ERD: Single mode handshower & overhead. Dual mode handshower or overhead.
2) Target Pure Play initially as fastest route-to-market.
2.1.2 Product Names Virtue.
3) Capitalise on consumer readiness to adopt different aesthetic styles and consumer 2.1.3 Style Heritage.
perception of 'heritage' as a more premium design. 2.2 Performance MUST HAVE WON'T HAVE
2.2.1 Control Type Rotational - Single Sequential Lever.
4) Contribute to an improved vitality and margin for the mixer shower category. 2.2.2 Temp. Rotation Angle Nominal 220° Rotation (as per realm).
2.2.3 Rotation Direction Anti-Clockwise On, through to hot.
Cost-Volume-Profit (CVP) 2.2.4 Control Requirements Smooth Feel – Benchmark Existing Realm.
1) For the consumer seeking a complete traditional bathroom styling, the Mira Virtue is a 2.2.5 Control Operating Torque 1.0Nm ± 0.1Nm.
heritage mixer shower that works on all systems and pressures, designed to complement the 2.2.6 Temp. Override None.
Virtue tap range, to provide a cohesive bathroom design and a frictionless shopping
2.2.7 Max. Temp. Setting 43°C.
experience.
2.2.8 Max. Torque 10Nm MINIMUM.
2) Unlike, Soak Traditional Thermostatic and The Bath and Co. Barrington, Mira Virtue 2.2.9 Temp. Control Retention Method Screw.
provides a complete bathroom brassware aesthetic, and because all Mira products work on 2.2.10 Force To Pull Off Temp. Control 150N MINIMUM - at lever end.
any system, it’s an easy consumer choice. 2.2.11 Shroud Torque Requirement 2Nm MINIMUM.
1 - Marketing 2.2.12 Flow Rate Through Handset at 0.1bar 4.5 l/min.
1.1 Customer Domestic. 2.2.13 Flow Rate Through Overhead at 0.1bar 5.2 l/min.
1.2 Branding Mira Showers. 2.2.14 Combined Outlet Flow Rate at 0.1bar 6.4 l/min.
1.3 Product Name Virtue. 2.2.15 Flow Rate Through Valve Only at 0.5bar 17 l/min.
1.4 Target Market UK. 2.2.16 Flow Regulators Supplied 12l/min.
The Bath Co. Barrington dual shower, Bristan 1901 dual shower, 2.2.17 Thermal Performance ± 2°C.
1.5 Competitors Soak traditional dual shower. 2.3 Design Detail MUST HAVE WON'T HAVE
1.6 Warranty 5 years. 2.3.1 Indicator Trims Chrome Plated ABS. Pad Printing or Laser etching.
1.7 MoSCoW Prioritisation 2.3.2 Temperature Control Rotational - Single Sequential Lever. No Override.
What must be delivered, i.e. it is essential for this project? Existing Realm Handset.
1.7.1 Use MIRA Realm as an overhead fitting. 2.3.3 Handset All spray modes must form a functional spray
1.7.2 Control handle design to match virtue taps. pattern at 0.1bar.
M(ust 1.7.3 KIWA approved. 2.3.4 Slide Bar None - Riser bars fitted for Overhead.
have): 1.7.4 Chrome finish. 2.3.5 Clamp Bracket None.
1.7.5 Must deliver minimum 4.5 l/min flow rate at 0.1 bar. 2.3.6 Hose (ERD ONLY) 1.75m H-Flex EN1113.
1.7.6 Unique handle design - at a minimum to differntiate from competitors. 2.3.7 Hose Retaining Ring None.
1.7.7 Clearly understood graphics for ease of use. 2.3.8 Soap Dish None.
What should be delivered as a high priority but is not essential? 2.3.9 Parking Socket As per current Realm.
S(hould 1.7.8 Use MIRA Realm as an overhead fitting. 2.4 Ergonomics MUST HAVE WON'T HAVE
have): 1.7.9 Aesthetically similar to Virtue taps. 2.4.1 Ergonomics Easy to use by all.
1.7.10 Easy to use controls - minimal turns of the handle to achieve full flow. 2.5 Size MUST HAVE WON'T HAVE
What could be delivered if there was available time / budget / resource? 2.5.1 Valve 153mm inlet centers.
C(ould
1.7.11 Differentiated body styling to realm, dependant on time and cost. 2.5.2 Overhead 200mm.
have):
1.7.12 Cost reduction activity on cartridge, body and fittings. 2.5.3 Diverter 313mm height from Valve center.
W(on't What would we have if time / budget / resource was unlimited? 2.6 Material Details MUST HAVE WON'T HAVE
have): 1.7.13 New diverter and clamp bracket design. 2.6.1 Material Detail 1 KIWA approval.
2.6.2 Material Detail 2 As per current Realm.
Product Design Specification
2 - Design 2 - Design
2.7 Installation MUST HAVE 2.12 Environment MUST HAVE
Gravity.
2.12.1 Bacterial Resistance Salt Spray Test 48 hours - specified with Chrome-plating standards.
Gravity pumped.
2.7.1 Plumbing systems Combi-boiler. 2.13 Visual Design Intent MUST HAVE
Mains unvented.
Thermal stores.
2.7.2 Stated Max. Static Pressure 10 bar.
2.7.3 Stated Max. Maintained Pressure 5 bar.
Visual link to Aspects Brassware.
2.7.4 Min. Maintained Pressure 0.2 bar at the valve.
ERD
2.7.5 Recommended Hot Supply 60-65°C.
Detail to be referenced from Virtue Shower CDL.
2.7.6 Max. Temp. Valve Can Withstand 85°C.
2.7.7 Cold Water Range 5-25°C.
Mechanical hub stop alignment. To adjust rotational travel of
2.7.8 Max. Temp. Adjustment
handle.
2.7.9 Pipe Centres 153mm ± 1mm (Fixed).
2.7.10 Inlet Distance From Wall 7mm.
2.7.11 Inlet Connections 15mm Compression, Hot - Left, Cold - Right.
2.7.12 Outlet ½” BSP Flat Face, Bottom - Outlet.
Visual link to Aspects Brassware.
2.7.13 Safe Touch No.
ER
2.7.14 Reversible Inlets Yes, must be not be a 4 port body.
Detail to be referenced from Virtue Shower CDL.
2.7.15 Rising And Falling Supplies Yes.
2.7.16 PCPs Standard PCPs.
2.7.17 Compression Nuts Mira Standard.
Mira Standard (supplied). Must work with Irish pipe and
2.7.18 Olives
Olives. 3 - Approvals and Testing
Back-Plate Screwed To Wall, Grub Screwed To Body, as per 3.1 Patents NONE.
2.7.19 Wall Mounting
current Realm. 3.2 Product Standards (Approvals) KIWA.
3.3 Materials Standards WRAS approved; BS6920 odour and flavour testing.
2.7.20 Filters Integral to the inlet elbows, as per current Realm.
4 - Manufacturing
2.7.21 Installation Template Yes. 4.1 Production Site Cheltenham
2.7.22 Exposed Retrofit Compatibility Realm. 4.2 Processes Manually build, test and pack in same cell as current Realm product.
2.8 Maintenance MUST HAVE 5 - Distribution
2.8.1 Temperature Issues Replace thermostatic cartridge assembly. 5.1 Shelf Life and Storage 1 year+.
2.8.2 Shut-off Issues Replace thermostatic cartridge assembly. 6 - Documentation
2.8.3 Spare Provision 10 years. 6.1 Product Manual Installation and User Guide (IUG)
2.9 Life in Service (Operation) MUST HAVE 6.1.1 PDF Online Required.
2.9.1 Field Trial (ERD and ER) 5. 6.1.2 Printed Required.
2.10 Product Life Span MUST HAVE 6.1.3 Multi Lingual Not required.
2.10.1 Design in Service Life 10 years. 6.1.4 Colour Not required.
2.11 Warranty Rate % MUST HAVE 6.2 Technical Data Sheet Required.
2.11.1 Embryonic Warranty 5%. 6.3 CAD Drawings - State Format Required - STP files.
2.11.2 Ongoing Warranty - ER Equal to or better than current Realm (6%). 6.4 Guarantee Card Required.
2.11.3 Ongoing Warranty - ERD Equal to or better than current Realm (7%). All documentation incl.
6.5 drawings, test reports, quality Required.
and approvals documents.
Mira-Kohler Critical Design Lines (CDL) Guidelines
Any deviation from these must be signed off by the design lead.
Temperature/Flow
Handle
155.7mm
User Trim Spokes to be at 45° when Handle

Graphics is at ‘Off’ position
Ceramic Branded
Bezel Virtue ERD Virtue ER
Not to scale
Ceramic Bezel
Text to be debossed into Shroud Artwork to be transfer positioned

component by 0.5mm on to Ceramic Bezel
How Mixer Taps Work
“Thermostatic mixing element: There’s a temperature sensitive element which expands or contracts depending
on the temperature of the water surrounding it. When the thermostatic element senses a temperature change,
it moves a piston which changes the proportion of hot and cold water being mixed in the valve. This move-
ment enables the valve to remain stable and to shut down in case of cold or hot water failure.
Piston Component: Usually connected to the thermostatic element, the piston moves back and forth over the
cold and hot ports of the valve, changing the proportion of hot and cold water entering the valve depending
on the temperature of the water.
Temperature adjustment: Autotaps thermostatic mixing valves have a temperature adjustment (usually located
at the top of the valve). Typically, this can be adjusted to change the position of the piston and therefore the
proportion of hot and cold water entering the valve.”
Autotaps, 2018. HOW THERMOSTATIC MIXER VALVES WORK?. [Online] Available at: http://www.auto-
taps.com/how-thermostatic-valve-work.html
Waters, R., 2018. Thermostatic mixing valves. [Online] Available at: https://www.hpac-
mag.com/features/1004124380/ [Accessed 20 11 2018].
Assumptions, Issues Identified After Initial Assessment & Corresponding Suggestions
SUPPLIERS OF INDIVIDUAL COMPONENTS
ALL OTHER PARTS

FROM THE UK
CLASSIC BODY ASSY
FROM CHINA
UK STANDARD PIPE CENTRE DISTANCES AND PIPE DIAMETERS UK STANDARD PIPE FITTING VARIETIES IN BATHROOMS
ASSUMPTIONS:
1) Since the supply of the Classic Body Assy is sub-contracted to China, it has been assumed that Mira would prefer not to have changes made to this component to make it easier to
continue placing orders for the part. The remaining components supplied by UK-based manufacturers will be the focus of this DFA exercise.
2) The Classic Body Assy is fitted to bathroom walls that have standard inlet pipe centre distances (153mm) and diameters (19mm). Therefore, it is assumed that the fasteners used to
secure the Classic Body Assy to the inlet pipes with elbow joints, as seen above, will remain out of scope for this analysis.
3) The Thermstream S8 Natural (Cartridge) has 37 components within it. It is used as a standard part in multiple assemblies at Mira. Therefore, it is assumed that the Thermstream S8
Natural is one single component out of the total of 14 components.
4) Functional parameters such as flow rate, thermal performance, water pressure and temperature ranges will remain unaffected by the redesign.
This leaves the product with 14 constituent components and 1 packaging component.
ISSUES IDENTIFIED:
1) The insertion of the O RING 55.6 X 2.4 is time-consuming.
2) The HUB and the BEARING are intermediate components that are not required for relative motion, and are not required to be separate for the product’s assembly or disassembly.
3) The VIRTUE SHROUD and the HANDLE BOTTOM do not qualify to be individual components.
4) A fastener that is used to secure the intermediate components to the handle can be investigated.
5) The BEZEL RETAINER, the BEZEL SPRING and the ADHESIVE PAD are components that add no value to the product or its functioning.
6) The text on the CERAMIC BEZEL needs to be horizontal on final assembly.
POTENTIAL DESIGN SOLUTIONS:

1) Eliminate intermediate components such as the HUB and the BEARING.
2) The VIRTUE SHROUD and the HANDLE BOTTOM can be incorporated into one component.
3) A material that serves the same purpose as the O RING 55.6 X 2.4 can be over-moulded onto the rim of the VIRTUE SHROUD.
4) The HANDLE WASHER and the M4 X 40 CAP SKT PATCHED fastener can be eliminated if the components underneath undergo radical design changes.
5) The BEZEL RETAINER and the BEZEL SPRING can be eliminated if a different means of securing and removing the BEZEL can be designed.
6) The CERAMIC BEZEL could potentially be incorporated with the HANDLE, which would also eliminate the need for the ADHESIVE PAD.
7) The logo on the CERAMIC BEZEL can be redesigned to fit within MIRA’s ethos, yet be oriented at any angle, saving time during assembly.
8) Secondary operations such as reorientations, adjustments, fastening and removing the plastic coating off of the ADHESIVE PAD could be reduced or eliminated.
Summary of Boothroyd Software Analysis
Product Structure Chart Category 1 - Parts for Elimination Category 2 - Fasteners for Elimination Category 2 - Separate Operations
SUMMARY OF RESULTS
15 3 5 10 16
9.47%
PARTS SUBASSEMBLIES THEORETICAL PARTS UP FOR SEPARATE
ANALYSED ANALYSED MINIMUM PARTS ELIMINATION OPERATIONS
including
packaging (14 + 1)
DESIGN EFFICIENCY
186.81s 15.30s
TOTAL ASSEMBLY
16.77s 33.44s
PARTS UP FOR
121.30s
SEPARATE
INSERTION OF THEORETICAL
TIME SUBASSEMBLIES MINIMUM PARTS ELIMINATION OPERATIONS
Product Worksheet from Boothroyd Software
Redesign Suggestions from Boothroyd Software Analysis
The redesign suggestions obtained from the Boothroyd DFMA software were used as a guideline for the redesign of the
product. The following conclusions were made:
1) Efforts will be made to eliminate adhesives and fasteners.

2) Intermediate components such as the Hub, Bearing and Handle Bottom will be eliminated.
3) The O-Ring was a time-consuming part to place on to the assembly. This will be investigated to make it quicker.
4) The packaging was found to be a bottleneck after the conversation with Mira. This will also be investigated.
MIRA VIRTUE
2 - OPPORTUNITY
IDENTIFICATION
MIRA VIRTUE - OPPORTUNITY IDENTIFICATION
Downselection of Practical Redesign Proposal
A Pugh Matrix was used to downselect a concept for development. The DFA Best Practice guidelines were used as criteria for comparison and each concept was scored compared to the original design, i.e. better, same or worse.
Mira Valve Redesign Ideas

KEY:
BETTER THAN ORIGINAL
SAME AS ORIGINAL
WORSE THAN ORIGINAL
Importance
Desirable Requirements Redesign 1 Redesign 2 Redesign 3 Redesign 4 Redesign 5
Rating (1-10)
Minimize Part Count 10 + + + + +
Self Locating Features 6 = = + + +
Self Fastening Features 8 = = + = =
Minimise Reorientations 8 + + + + +
Design for Retrieval,

6 + + = = +
Handling, Insertion
Design for Top Down
6 + + + + +
Assembly
Standardise Parts 7 + + + + +
Encourage a Modular
5 + + + + +
Design
Design Base Part to Locate
6 = = + + =
Features
Design Component
8 = = = - =
Symmetrically
Total Score + 6 6 8 7 7
Total Score = 4 4 2 2 3
Total Score - 0 0 0 1 0
Total Weighting Score
Numerical 42 42 56 40 48
(Compared with Original
Idea 3 was the highest rated, with idea 5 coming in second place. These ideas were further analysed by the group to downselect one final proposal.
Pros and Cons of Final Practical Concepts
IDEA 5 IDEA 3
• Vertical assembly.
• Minimum number of parts 5 from 14. • Minimum number of parts 5 from 14.
PROS
• Maintains functionality without compromising on PROS
• Elimination of non-value added operations.
aesthetics. • Maintains functionality without compromising on
• Meets Mira’s key requirements. aesthetics.
• Meets Mira’s key requirements.
• Too complex.
• Alignment issues.
• Increased tooling costs.
CONS • Didn’t conform with vertical assembly. CONS • Clips could break, especially during disassembly.
• Large re-design for small improvements.
• Difficult to disassemble.
Ideas 3 and 5 from the Pugh Matrix were compared in more detailed, outweighing pros and cons to come to a conclusion regarding which concept was finally chosen.
Since Idea 3 had more pros and fewer cons, it was chosen to be developed further in the detail design phase.
The clips shown in the drawing attached to the Handle had the potential to break, which would result in an entire handle to be replaced, so the clips were swapped with the cap on the cartridge which is a cheaper and easier part to
replace if broken.
Downselection of Blue Skies Redesign Proposal
A Pugh Matrix was used to downselect a blue skies concept for development. The DFA Best Practice guidelines were used as criteria for comparison and each concept was scored compared to the original design, i.e. better, same or worse.
Mira Valve Blue Skies Concepts

KEY:
BETTER THAN ORIGINAL
SAME AS ORIGINAL
WORSE THAN ORIGINAL
Importance
Desirable Requirements Redesign 1 Redesign 2 Redesign 3 Redesign 4 Redesign 5 Redesign 6 Redesign 7 Redesign 8 Redesign 9
Rating (1-10)
Minimize Part Count 10

+ + + + + + + + +
Self Locating Features 6

+ + = - + + + + +
Self Fastening Features 8

= + + - + + + + +
Minimise Reorientations 8
+ + + = + + - + +
Design for Retrieval, Handling,
6
Insertion + + + + + + = + +
Design for Top Down
6
Assembly = = = = = = = = =
Standardise Parts 7
+ + + - + - + = +
Encourage a Modular Design 5

+ + + + + + + + +
Design Base Part to Locate
6
Features = + + + + + + + +
Design Component
8
Symmetrically - - = - - - - + +
Total Score +
6 8 7 4 8 7 6 8 9
Total Score =
3 1 3 2 1 1 2 2 1
Total Score -
1 1 0 4 1 2 2 0 0
Total Weighting Score
(Compared with Original) Numerical
34 48 50 -2 48 34 26 57 64
A Pugh Matrix was used to determine which blue skies design was the most feasible. The desirable requirements were chosen with the aim of reducing assembly time. Based on these requirements, Redesign 9 scored 64, the
highest total mark. Redesign 9 consisted of the following components; Classic Body Assembly, S8 Thermstream Natural, and Shroud containing a standardized button. The shower would activate for a pre-defined amount of time
and at a set temperature upon a button press. Other blue skies concepts provided a more unique redesign approach, but due to the design requirements set, Redesign 9 provided the greatest opportunity for reducing assembly
time and costs.
MIRA VIRTUE
3 - PROPOSAL
OF
ALTERNATIVES
MIRA VIRTUE - PROPOSAL OF ALTERNATIVES
Redesigned Mira Virtue - Redesigned Components
False bolt head incorporated

into handle to maintain
aesthetics Groove to snap on to the
rim on the Virtue Shroud
Fasteners and
adhesives
eliminated
Stops added in groove

to engage with the
cartridge and control
water
flow/temperature New locating feature that
snaps on to the red clip on
the cartridge
NEW HANDLE
Wall height
Newly designed Shroud has 90 degrees of rotational symmetry.
increased to snap
The debossed graphics were designed using a Serif font that
on to Handle
maintained the ‘Heritage’ look of the product.
Red top on
Thermstream
redesigned to snap into
groove in Handle
O-Ring over-moulded into inner diameter of Shroud
NEW VIRTUE SHROUD NEW CLIPS ON THERMSTREAM

Redesigned Mira Virtue - Redesigned Component Interfaces
Snap fit feature that

rotates inside the
groove
Stops engage with teeth/clips in

the Thermstream to rotate the
system
HANDLE-SHROUD CONNECTION
HANDLE-THERMSTREAM CONNECTION
HANDLE-SHROUD-THERMSTREAM CONNECTION
Redesigned Logo
The aim was to make a logo that had 90 degrees of rotational symmetry to reduce reorientation time during
assembly.
The alphabets ‘M’ (Mira) and ‘V’ (Virtue) were manipulated to create the logos above.
The Ceramic Bezel will no longer need to be removed for disassembly.
It is a one-time snap fit component.
The above logos would ensure 90 degrees of rotational symmetry, reducing reorientation time.
Redesigned Packaging
Exploded View Showing Components in Redesigned Mira Virtue
TOTAL NUMBER OF
NUMBER PARTS AFTER
OF PARTS EVALUATION
42
incl. Cartridge
5
sub-assembly
VIRTUE SHROUD
CLASSIC BODY ASSY

HANDLE
CERAMIC BEZEL
LIST OF COMPONENTS
1 THERMSTREAM S8 NATURAL
2 CLASSIC BODY ASSY
3 HANDLE
4 VIRTUE SHROUD
5 CERAMIC BEZEL
New Graphical Assembly Sequence
1 Load Body into fixture
2 Grease inside of Body
3 Insert Thermstream into Body
3 9
4 Screw down headnut
5 Shut off cartridge (Thermstream)
6 Locate into fixture & test
7 Place body into assembly fixture

10
8 Affix date label to Shroud
9 Locate Shroud on to Body and push down
11 10 Locate Handle on to Thermstream clips and grooves

on Shroud and push down to snap fit
11 Snap fit Bezel into Handle
Standard pipe fitting operations and a post-op inspection take place after operation 11.
4 fixtures, 2 hand tools and 2 additional assembly aids will be used in production.
New Tools, Fixtures, Jigs, Assembly Aids and Workstations
Aid Image Use Redesign

Fixture J22852 Load CLASSIC BODY ASSY Retained
Air Driver 10.0Nm Start Headnut thread by hand and screw down to Retained
Driver Bit J22855 correct torque
Hand tool J22847 Turn the hub fully clockwise to shutoff Cartridge Retained
ADLT Fixture Locate assembly in ADLT fixture and test to PPTR 268 Retained
PPTR 268
Assembly Fixture J24324 Place Body assembly int assembly fixture J24324 Retained
Assembly Aid J24326 Push down on top of Shroud so that it is fully closed Retained
Fixture J24324 Locate BEZEL RETAINER assembly and locate I fixture Removed
HAND TOOL J24327 Using handtool insert BEZEL SPRING into Bezel Retainer Removed
HAND TOOL J24325 Remove Bezel Retainer assembly from fixture and Removed
locate into Handle assembly. Using handtool push
down and rotate 90 degs clockwise
The table on the left-hand side shows the list of tools (orange), fixtures (green), and assembly aids (blue).
The last column in the table mentions whether the tools, fixtures and assembly aids have been eliminated or retained.
Assembly Fixture 24269 Pick up Body Assembly and place in fixture Retained
The tools and fixtures used for the bezel retainer were removed as the part was eliminated.
The image on the right-hand side depicts the workstation that could be used to assemble the Mira Virtue mixer valve.
MIRA VIRTUE
4 - COMPARISON
TO
ORIGINAL
MIRA VIRTUE - COMPARISON TO ORIGINAL
Old vs. New Product Structure Chart
ORIGINAL REDESIGN
Old vs. New Analysis Totals
ORIGINAL REDESIGN
Old vs. New Part Count
ORIGINAL REDESIGN
Old vs. New Assembly Time
ORIGINAL REDESIGN
Old vs. New Exploded View
TOTAL NUMBER OF
O RING 55.6 X 2.4
NUMBER PARTS BEING
OF PARTS EVALUATED
51
incl. Cartridge
14
sub-assembly
CLASSIC BODY ASSY HUB
VIRTUE SHROUD
HANDLE
ORIGINAL
LIST OF COMPONENTS
M4 X 40 CAP SKT PATCHED
BEARING
2 CLASSIC BODY ASSY
3 HANDLE
4 HUB
5 CERAMIC BEZEL BEZEL RETAINER
6 O RING 55.6 X 2.4 CERAMIC BEZEL
7 VIRTUE SHROUD HANDLE BOTTOM
8 BEARING
9 HANDLE WASHER
10 M4 X 40 CAP SKT PATCHED
11 BEZEL RETAINER HANDLE WASHER
12 ADHESIVE PAD
BEZEL SPRING
13 BEZEL SPRING
14 HANDLE BOTTOM ADHESIVE PAD
TOTAL NUMBER OF
NUMBER PARTS AFTER
OF PARTS EVALUATION
42
incl. Cartridge
5
sub-assembly
VIRTUE SHROUD
REDESIGN CLASSIC BODY ASSY

HANDLE
CERAMIC BEZEL
LIST OF COMPONENTS
2 CLASSIC BODY ASSY
3 HANDLE
4 VIRTUE SHROUD
5 CERAMIC BEZEL
Summary of Improvements
ORIGINAL REDESIGN
Total Parts Total Parts
15 60%
DECREASE
6
Sub-Assemblies Sub-Assemblies
Design Efficiency 3 100%

DECREASE
0 Design Efficiency
9.47 Separate
Operations
16 31.25%
Separate
Operations
11
12.44
DECREASE
Assembly Assembly
Time Time
186.81s
39.74%
DECREASE
112.57s
31.36
INCREASE IN DESIGN EFFICIENCY
MIRA VIRTUE
5 - FEASIBILITY
ASSESSMENT
MIRA VIRTUE - FEASIBILITY ASSESSMENT
Comparison vs. DFA Best Practice Guidelines
Design for Good Practice ✓/✗ Final Design Feasibility
The design has been simplified to reduce to its

Design for top down
✓ elementary parts. This allows for pure vertical
assembly
assembly.
This was not entirely feasible for this particular design.

Make parts self-locating ✗ All parts are self-locating, excluding the clip. This
requires the correct orientation to ensure functionality.
Symmetry was a key aspect to the redesign, reducing

Try to design parts with the degrees of freedom. Additionally, detailed features
✓
symmetry such as the Mira logo and the Hot/Cold imprint were
considered and adapted to allow for symmetry.
If symmetry is not possible Where most features are symmetrical, the clip requires
then make it obvious that the specific alignment. This was made clear by having just
✓
part needs a specific two parallel locators with defined insertion slots in the
orientation therma stream.
Prevent stacked parts from

✓ The spring on the original design was removed to
getting stuck together or
minimise the risk of tangling.
tangled using features
All small and delicate parts were eliminated in the

design stages. This includes the spring, adhesive pad,
Avoid parts that are difficult
✓ washers, hub and the bearing. By combining or
to handle
removing components, the remaining 5 parts are of
suitable handling size.
Avoid parts that only connect.

Try and bring other parts The bezel retainer was a connection part, that has
✓
together to eliminate the been removed in the redesign.
connection
Conformance to Product Design Specification (PDS)
Design Evaluated
KEY:
CONFORMS TO SPECIFICATION
DOES NOT CONFORM TO SPECIFICATION
PDS Section PDS Number PDS Statement Development of Statement Original Product Redesigned Product Blue Skies Approach Comments (Redesign) Comments (Blue Skies)
Ceramic bezel would change material to Ceramic bezel will be replaced with a button,
1.0 Control handle design to match virtue taps.
prevent cracking however this could be a 'heritige' design
Product redesign could maintain the original Button and Shroud could remain coated with a
1.1 Chrome finish.
chrome finish chrome finish
Marketing
1.0 Marketing 1.3 Unique handle design - at a minimum to differntiate from competitors. Handle non-existant in blue skies redesign
Graphics changed on redesign to Standardized button would be considered self-

1.4 Clearly understood graphics for ease of use.
accommodate a more symetrical design explanatory and therefore easy to understand
Pre-set temperature, only required to press the
1.5 Easy to use controls - minimal turns of the handle to achieve full flow.
button to activate the shower
"'Virtue" could still be branded on the handle
2.1.1 Product Names Virtue. Product would be branded as a new line
design
Style of redesigned product could remain
2.1.2 Style Heritage. Product would be branded as a new line
"Heritage"
2.1.3 Ceramic Branded Bezel Ceramic material changed for the bezel Bezel becomes obselete in the design
2.1 Aesthetics
2.1.4 Text to be debossed into Shroud component by 0.5mm Text not required
2.1.5 Spokes to be at 45 degrees when the handle is at "off' position Handle becomes obselete with the blue skies design
2.1.6 Artwork on ceramic bezel to be horizontal when in "off" position Logo to be symetrical so Beta value decreases Handle becomes obselete with the blue skies design
Lever would become obselete in the blue skies

2.2.1 Control Type Rotational - Single Sequential Lever.
concept
Lever would become obselete in the blue skies
2.2.2 Temp. Rotation Angle Nominal 220° Rotation (as per realm).
concept therefore no rotation required
2.2 Performance 2.2.3 Rotation Direction Anti-Clockwise On, through to hot. Handle becomes obselete with the blue skies design
Design
2.2.4 Control Requirements Smooth Feel – Benchmark Existing Realm. Button could have a smooth feel
Snap fit locates the handle to the S8

2.2.7 Temp. Control Retention Method Screw. Screw is no longer required in the product
Thermstream Cartridge
2.3.1 Indicator Trims Chrome Plated ABS.
2.3.2 Temperature Control Rotational - Single Sequential Lever. Handle becomes obselete with the blue skies design
2.3 Design Detail
2.3.3 Hose Retaining Ring None.
2.3.4 Soap Dish None.
Standardized button would be considered self-

2.4 Ergonomics 2.4.1 Ergonomics Easy to use by all.
explanatory and therefore easy to understand
2.5.1 Valve 153mm inlet centers. Sizes may vary for the redesigned product Sizes may vary for the blue skies approach
2.5 Size 2.5.2 Overhead 200mm. Sizes may vary for the redesigned product Sizes may vary for the blue skies approach
2.5.3 Diverter 313mm height from Valve center. Sizes may vary for the redesigned product Sizes may vary for the blue skies approach
Consideration of Automation
NT/NA 14/5 = 2.8
Payback Period 4 Shift-Years
Annual Production Volume
Due to the low production volume of 1,600, automation is not

applicable. This is justified as the minimum value shown on the
graph is 50,000. If production were to increase, the annual
production volume would need to be 430,000 units to justify
the use of a single-station one robot arm.
As the demand for the Mira Virtue ERD is unlikely to reach this
level of demand, automation should not be considered.
However, the re-design of the product will enhance manual
assembly and make assembly more efficient.
Cost and Profit Analysis
1.63% of the total manufacturing cost was reduced due to the elimination of the parts 35.40% of the manufacturing cost out of the 12 investigated parts (excluding Body and
highlighted in green. Thermstream) was reduced due to the elimination of the parts highlighted in blue.
0.39% ASSEMBLE & TEST MODULE (1332278) Out of Total Out of 14 Parts Out of 12 Parts
0.65% ASSEMBLE & TEST MODULE (1332278) # Split % Split % Split % Component
8.29% 8" DELUGE SHOWERHEAD 1 0.1282 12.82% 0.3919 39.19% N/A N/A THERMSTREAM S8 NATURAL
4.96% TRADITIONAL HANDSHOWER 2 0.1528 15.28% 0.4672 46.72% N/A N/A CLASSIC BODY ASSY
3.04% HOSE 1.75M H-FLEX EN1113 3 0.0205 2.05% 0.0627 6.27% 0.4448 44.48% HANDLE
20.55% TRADITIONAL DIVERTER ASSY 14 0.0078 0.78% 0.0237 2.37% 0.1685 16.85% HANDLE BOTTOM
3.34% RISER PIPE BENT CHROME 7 0.0049 0.49% 0.0151 1.51% 0.1070 10.70% VIRTUE SHROUD
0.82% DIVERTER PIPE CHROME 5 0.0030 0.30% 0.0092 0.92% 0.0649 6.49% CERAMIC BEZEL
1.64% RISER PIPE LONG 13 0.0018 0.18% 0.0054 0.54% 0.0383 3.83% BEZEL SPRING
5.03% BRACKET CHROME 11 0.0014 0.14% 0.0043 0.43% 0.0308 3.08% BEZEL RETAINER
0.40% MINI PIPE CONCEALING PLATE CHROME 4 0.0014 0.14% 0.0043 0.43% 0.0304 3.04% HUB
0.10% O KEY 6 0.0013 0.13% 0.0041 0.41% 0.0292 2.92% O RING 55.6 X 2.40
0.29% HEADNUT SOCKET 10 0.0013 0.13% 0.0039 0.39% 0.0279 2.79% SCREW M4 X 40 CAP SKT PATCHED
1.16% COMPONENT PACK ERD 8 0.0013 0.13% 0.0039 0.39% 0.0276 2.76% BEARING
1.68% 18MM COMPRESSION NUT CHROME 12 0.0010 0.10% 0.0032 0.32% 0.0225 2.25% STICKY PAD
0.18% OLIVE 18MM DZR BRASS 9 0.0004 0.04% 0.0011 0.11% 0.0080 0.80% HANDLE WASHER
0.23% IUG MIRA VIRTUE
0.04% INSTALLATION TEMPLATE Cost reduc�on due to reduced parts = 35.40% ELIMINATED PARTS
0.01% GUARANTEE REGISTRATION CARD
0.01% POLY BAG 10" X 12"
1.12% CARTON VIRTUE
1.10% INNER FITMENT
The reduction in assembly time was used to work out the yearly gross profit accomplished by Mira. An operator efficiency of 75% was assumed, and
0.11% LABEL VIRTUE ERD TOP
an hourly rate of £35 including overheads was assumed for the operators. Using a RRP of £525, an increase of 0.18% was observed in gross profit. The
0.00% LABEL BLANK PRODUCT IDEN 25x10mm
uncertainties in the values obtained by the software could potentially be made more accurate using real assembly times, perhaps by timing a series
12.82% THERMSTREAM S8 NATURAL
of operators assembling a batch of parts to obtain a before and after assembly time. The figure could be made more accurate for Mira by analysing
0.14% HUB
15.28% CLASSIC BODY ASSY Parts being inves�gated 14+1 packaging
the parts and tools that have not been highlighted in the table on the left-hand side.
2.05% HANDLE Eliminated parts 8 parts (1.63% of total) Parameter Unit Old New Difference vs. Old Comments
0.78% HANDLE BOTTOM Theoretical assembly time per part seconds 186.81 112.57 74.24 Decrease Assuming Boothroyd analysis times are representative of what is seen on the shop floor.
Load Factor (Operator Efficiency) out of 1 0.75 0.75 Operator efficiency of 75% is assumed.
0.30% CERAMIC BEZEL Actual assembly time per part seconds 249.08 150.09
0.14% BEZEL RETAINER Parts produced per year parts 1600.00 1600.00
0.10% STICKY PAD Assembly time per year seconds 398528.00 240149.33
Assembly time per year minutes 6642.13 4002.49
0.18% BEZEL SPRING
Assembly time per year hours 110.70 66.71
0.49% VIRTUE SHROUD Hourly rate including overheads £/hour 35.00 35.00 Manual assembly (rate of £20 per hour is assumed).
0.13% BEARING Overtime hourly rate £/hour 0.00 0.00 Not implemented.
Total hourly manufacturing cost £/hour 35.00 35.00
0.13% SCREW M4 X 40 CAP SKT PATCHED
Total yearly manufacturing cost £ 3874.58 2334.79 1539.79 Decrease 40% decrease in manufacturing costs.
0.04% HANDLE WASHER Manufacturing cost per unit £ 2.42 1.46 0.96 Decrease 40% decrease in manufacturing costs.
0.56% 18MM COMPRESSION NUT CHROME Retail price per unit £ 525.00 525.00
0.06% OLIVE 18MM DZR BRASS Gross profit per unit £ 522.58 523.54 0.96 Increase 0.18% increase in gross profit.
0.01% SCREW M5X6 SKT SET PCP A2 Profit margin out of 1 0.9954 0.9972
Profit margin % 99.54 99.72 0.18 Increase 0.18% increase in gross profit.
0.13% O RING 55.6 X 2.40
Yearly revenue £ 840000.00 840000.00
0.70% COMPRESSION NUT 88/415 Gross profit (yearly) £ 836125.42 837665.21 1539.79 Increase 0.18% increase in gross profit.
0.06% OLIVE 15MM BRASS (DZR)
1.94% FINAL PACK
3.22% FINAL PACK
Assembly Testing of 3D Printed Parts
Assessment by Mira
ITERATION 1 ITERATION 2
Redesigned Part/Feature Visualisation of Redesigned Part/Feature Feedback from Mira Recommendations for Next Iteration Visualisation of Recommendation Feedback from Mira
1) Handle orientation/position is not defined. i) Redesign so that spokes in handle are

Good
Alignment features required for the off position. oriented at 45 degress in 'off' position.
a) This would be cost prohibitive,

Handle
display products, websites, catalogues
a) Other Mira products with the same handle
would need to be updated.
geometry could be redesigned to be better suited
ii) a) Redesign handle form so that it is easier for casting - this is unfeasible.
b) Complex tooling and increased
2) Tool split is unachievable with this form. The to die cast by adding draft angles (avoid
finishing/ polishing to remove shutter
underside of handle creates an undercut in the undercutting). b.1) Using a multiple part mould (three or four
lines and draft angles.
zinc die casting tool. sections).
b) Change the casting method.
c) Investment casting is more labour
b.2) Investment casting can be used instead of die
intensive and gives a coarse finish
casting.
which would need expensive post
processing.
iii) a) Removable cover on outer rim of the shroud.

iii) a) Cover the outer rim of the shroud while
chrome-plating to keep the region
a) Overmoulding needs to be done
uncontaminate, followed by overmoulding of
3) Over moulding a seal on the shroud can not before plating - this is not feasable.
the seal.
be done as this part is chrome plated.
b) Good idea.
b) Add the O Ring back into the product
structure.
Virtue Shroud
4) Graphics are very small and possibly iv) Redesign graphics to be larger and easier to Nice idea but this aesthetic would not
confusing. They need to be readable at a interpret at a glance using the words 'HOT' and be taken forward. Cost gain is not high
glance. 'COLD' instead of 'H' and 'C'. enough vs product visual compromise.
5) A bearing is needed to prevent chrome to v) Add an insert into the groove in the handle Wall sections are impossibly thin but
Handle-Shroud Connection
chrome contact. Parts will graunch. to prevent metal-to-metal contact. this concept is sound.
Assessment by Mira
Curved clips do not flex well. Strength,

6) These clips are too small, they will not be
vi) Increase the size (arc length) of the clips to clearance for tolerance stack and
strong enough to retain the handle and drive
be 0.25 x circumference. removal for servicing are still a concern
the cartridge.
with this concept.
New Clip Attachment on

Thermstream
7) There are conflicting requirements on the

material properties i.e. it is currently glass filled vii) a) Have 2 different materials, Acetal for the
nylon for good strength and rigidity on the clip and glass filled nylon for the base, solvent- Good idea.
stop. The clip needs to be flexible so the bonded externally and sent to Mira as one part.
handle can be removed for max temp setting.
8) These features are too small and will snap

viii) Same as vi). Still a concern.
when the user hits the max temp stop.
ix) Same as vi).

0.25 x circumference for the arc lengths of the
Handle-Thermstream 9) There will be a lot of slack/backlash in the clips with just under 0.25 x circumference for
Still a concern.
Connection rotation. This is a quality feel indicator. the slots in the handle would reduce slack
drastically and make the structure more rigid,
reducing chances of snapping.
It is understood that the handle will be

supported by the trim. Clearance is
needed to alow for the tolerance build
on the clips - this will cause the handle
x) Mechanism appears to be wobbly due to the
10) It will be wobbly unless supported by a to be wobbly.
absence of the shroud in the adjacent image.
bearing.
The shroud will stabilise the system of parts.
Options - reduce the tolerance build or
counter clearance with a spring to make
sure the handle is always loaded
against the bearing.
Assessment by Mira
11) You also need to consider the large

tolerance build that determines this fit. In the xi) A DVA analysis can be performed to ensure
Handle-Shroud-
setup shown this fit is determined by many that the components line up within the N/A As above.
Thermstream Connection
parts and clearance will be needed to make tolerances specified during assembly.
sure the clips can always be engaged.
xii) An off-white polymer can be used to make

the bezel while mimicing the aesthetics of the
12) How is the Ceramic Bezel assembled and Good idea, polymer may need a filler
Cermaic Bezel old ceramic part. This will be snap fitted into
retained? to make it feel like ceramic.
the handle. The new logo on the bezel will allow
for 90 degrees of rotational symmetry.
The adhered rig could be expensive

Packaging All points on packaging have been discussed separately. and add bulk to the flatpack. Other
than this, good concepts.
“Don’t be disheartened by the comments – it is incredibly difficult to implement in retrospect; some inefficiencies are baked into the design at initial concept stage.
There are good suggestions here and with a blank sheet design most could be implemented effectively, well done.”
The above comments were provided by Mira after two iterations of the product were proposed to them. Due to the time constraints of the project, no further iterations will be made though there is more scope for development.
Assessment by Mira
MIRA VIRTUE
6 - PRODUCT &
PROCESS CHANGES
MIRA VIRTUE - PRODUCT & PROCESS CHANGES
Changes in Product Design
Clips made larger to prevent them from snapping and reduce/eliminate slack/backlash.
Arc length of each clip = 0.25 x circumference.

Spokes point at New grooves to reduce
45 degrees when slack in connection to
in ‘off’ position thermstream Before After
Glass filled nylon (A) and acetal (B) can be

solvent-bonded to create a strategic
component with two material properties in
the regions required
HANDLE - ITERATION 2 THERMSTREAM CLIP - ITERATION 2

Changes in Interfaces Between Components
Handle hidden to show

engagement of shroud Upper rim of shroud
Without bearing with bearing has a protrusion
that snaps into the
channel created by
New bearing slots the bearing
into handle and
provides tracks for
rotation about the
shroud
With bearing
HANDLE-SHROUD CONNECTION HANDLE-SHROUD-THERMSTREAM CONNECTION
Clips made larger to prevent them from snapping and reduce/eliminate slack/backlash. The bezel is to be snap fitted
Grooves in Handle also changed in dimension to reduce/eliminate slack/backlash. into the handle with the help of
Arc length of each clip = 0.25 x circumference with a 0.25mm clearance on either side of each clip and the walls of the grooves in the handle. tiny protrusions that locate into
similar-shaped grooves in the
handle.
The material of the bezel would

have to be changed to a
polymer that is finished to look
like the old ceramic bezel.
HANDLE-THERMSTREAM CONNECTION BEZEL-HANDLE CONNECTION

Changes in Interfaces Between Components
CERAMIC BEZEL AND HANDLE THERMSTREAM CLIP REDESIGN
Ceramics and metals are typically joined in one of two ways:

1) Adhesives
2) Brazing/Soldering
Both want to be removed for this process as adhesive pads add an extra part and brazing or soldering
is a very time consuming process. For brazing and soldering the ceramic needs a metal coating to
allow the bonding between the parts.
Other options can include:

1) Transient Liquid Phase Bonding
2) Ultrasonic Joining
3) Infiltration Processes
4) Microwave Joining
5) Sol Gel
All these processes are again, very time consuming and not a viable option when considering it in the
context of the bezel and the handle.
An option could be to put a thread on the bezel and on the handle to screw the bezel into the handle.
The difficult with this is brittleness however it is not a load bearing part. Assembly would need to be
done carefully so not to damage the bezel.
PLASTIC BEZEL AND HANDLE
The bezel could be plastic and designed to look like ceramic. The same materials can be used that are currently used for the bearing (acetal) and hub (glass filled
nylon). The design will need to incorporate grooves from the stronger material (glass filled nylon) to
If this was done the most obvious joining method would be snap fit. This joining method is used take the load when rotating, but use of grooves will also allow the acetal to flex and bend when
elsewhere in the redesign and it a suitable option. The bezel does not need to be removed so needed to be removed. The parts can each be injection moulded and the solvent bonded together.
therefore disassembly is not a concern. This also resolves the injection moulding issue that was previously found with the clip due to its highly
complex shape.
Similarly a thread could be used so the bezel is screwed in.
Both materials can be difficult to bond due to their surface lubricity, however a cyanoacrylate adhe-
Converting the bezel to plastic would be desirable however it must have the aesthetics of ceramic to sive can be used as this offers the best strength and can be used with both glass filled nylon and
keep in line with the PDS. acetal. This part can be bought from a supplier as one part to be used in the mixer valve.
S-Bond, 2011. Ceramic to Metal Bonding. [Online] Available at: http://www.s-bond.com/- Permabond, 2018. Bonding Nylon/Polyamide with Industrial Adhesive. [Online] Available at:
blog/2011/04/04/ceramic-metal-bonding-part-one/ [Accessed 02 12 2018]. https://www.permabond.com/2015/03/18/bonding-nylonpolyamide-industrial-adhesive/ [Accessed
3 12 2018].
AZoM, 2001. Ceramic Joining - An Overview. [Online] Available at: https://www.azom.com/article.as-
px?ArticleID=1078 [Accessed 2 12 2018]. Permabond, 2018. How to Bond Acetal? Achieve success bonding Acetal. [Online] Available at:
https://www.permabond.com/materials_bonded/how-to-bond-acetal/ [Accessed 3 12 2018].
Guire, E. D., 2014. ‘Fastenating’—The art of making and testing ceramic screws (with video). [Online]
Available at: https://ceramics.org/ceramic-tech-today/fastenat-
ing-the-art-of-making-and-testing-ceramic-screws-with-video [Accessed 2 12 2018].
Changes in Assembly Processes
Refer to Graphical Assembly Sequence for Original and Redesigned parts to view the following sequence.
Assembly Processes
Original Redesign
Load Body into fixture Load Body into fixture

Grease inside of Body Grease inside of Body
Insert Thermstream into Body Insert Thermstream into Body
Screw down headnut Screw down headnut
Shut off cartridge (Thermstream) Shut off cartridge (Thermstream)
Locate into fixture & test Locate into fixture & test
Place body into assembly fixture Place body into assembly fixture
Locate Bearing Affix date label to Shroud
Locate Hub Locate Shroud on to Body and push down
Locate O Ring Locate Handle on to Thermstream clips and grooves
on Shroud and push down to snap fit
Locate Handle Bottom on to Hub Snap fit Bezel into Handle
Push down Shroud
Affix date label to Shroud
Locate Shroud on to Body
Locate Handle in to Hub
Locate Washer on to Screw
Locate Screw+Washer in Handle
Locate Bezel Retainer in fixture
Insert Bezel Spring into Bezel Retainer
Remove Bezel Retainer+Bezel Spring from fixture and locate
Remove backing from Stick Pad; locate in recess of Bezel Retainer
Remove backing from Stick Pad; locate Bezel on to Pad
Changes in Manufacturing Tools
Die Casting the Handle

The handle will need to be redesigned to be die casted. Due to the changes in the design of the handle it
cannot be removed from the mould without being damaged. The handle redesign will need to consider
draft angles and undercutting to make sure the part does not get damaged when being removed. Redesign
could be avoided as the handle is in keeping with other products in the same range. Any changes made to
the handle shape will then need to replicated across the other parts.
A mould consisting of multiple parts could be used to overcome the issue. However this makes the process
more complex and therefore more expensive. With multiple part moulds there is more opportunity for
error and potential waste.
Investment Casting the Handle

Investment casting is better for low production volume parts due to the as the initial costs of die casting are very
high although calculations would need to be carried out to determine which option is cheaper in the long run.
Investment casting offers a wider range of material choices should Mira decide to change material in future there
is greater options with investment casting. Investment casting has a far superior finish to die casting. Tolerancing
is tight however not as tight as die casting.
NADCA Design, 2018. Die Casting vs Investment Casting. [Online] Available at: http://www.diecastingdesign.org/investment-casting [Accessed 3 12
2018].
East West Manufacturing, 2018. Investment Casting vs. Die Casting: 7 Considerations When Choosing a Process. [Online] Available at: https://news.ew-
mfg.com/blog/investment-casting-vs.-die-casting-considerations-when-choosing-process [Accessed 3 12 2018].
Dynacast, 2018. WHAT IS THE DIFFERENCE BETWEEN DIE CASTING AND INVESTMENT CASTING?. [Online] Available at: https://www.dyn-
acast.com/what-is-the-difference-between-die-casting-and-investment-casting [Accessed 3 12 2018].
Injection Moulding the Virtue Shroud

Injection moulding of the virtue shroud
cannot be done using the above moulds. A
more complex mould, such as the one shown
to the left will need to be used.
Protolabs, 2018. Creating Complex Undercuts with Bumpoffs.

[Online] Available at: https://www.protolabs.co.uk/re-
sources/design-tips/creat-
ing-complex-undercuts-with-bumpoffs/ [Accessed 2 12 2018].
Changes in Manufacturing Tools
Ceramic Injection Moulding the Bezel

Ceramics can be injection moulded to create components. The mould will also need to be the same as shown
below however with a different cavity.
Protolabs, 2018. Creating Complex Undercuts with Bumpoffs. [Online] Available at: https://www.protolabs.co.uk/resources/design-tips/creat-
ing-complex-undercuts-with-bumpoffs/ [Accessed 2 12 2018].
Morgan Advanced Materials, 2018. Ceramic Injection Moulded (CIM) Components. [Online] Available at: http://www.morgantechnicalceram-
ics.com/en-gb/products/ceramic-injection-moulded-components/ [Accessed 2 12 2018].
Injection Moulding the Clip

The clip is a very complex part due to lots of extrusions and small details on the part. Injection moulding will be
difficult as the mould needs to be removed after the process has been completed. The mould needs to be
designed in a way that allows it to be removed whilst not damaging the clip. The mould will look like the image
below however with a different cavity shape. More than one part will be moulded each time and then snapped
off a spine.
Manufacturing Solutions Group, 2018. Injection Moulding. [Online] Available at: https://manufacturingsolutionsgroup.com/injection-molding-exp-
lained/ [Accessed 2 12 2018].
Changes in Manufacturing Processes
Refer to previous pages on changes in manufacturing processes for each component for more detail.
Manufacturing Processes
Original Part Redesign Part
Die Casting • Classic Body Assembly Die Casting • Classic Body Assembly
• Virtue Shroud
• Handle Bottom
• Handle
Plating • Virtue Shroud Plating • Handle
• Handle Bottom • Virtue Shroud
• Handle
Injection Moulding • O-Ring Injection Moulding • Clip
• Hub • Bezel
• Bearing • Virtue Shroud
• Washer
• Bezel Retainer
Ceramic Moulding • Ceramic Bezel Solvent Boding • Clip
N/A • Screw Investment Casting • Handle
N/A • Polybag
N/A • Spring
N/A • Adhesive Pad
EVALUATION AGAINST AIMS & CONCLUSION
A DFA investigation was carried out on Mira’s ‘Heritage’ Virtue mixer valve. The analysis consisted of 14 components, of which 2 could not
be removed including the classic body and the S8 thermstream natural (cartridge) sub-assemblies. However, the S8 thermstream natural
was adapted to incorporate snap fits to connect directly to the handle. Changes to the remaining parts resulted in a total part count
reduction from 12 to 3, eliminating 9 components. The 3 parts that remained present in the redesign included a modified virtue shroud,
original handle with snap fit female housing and the ‘heritage’ ceramic bezel. The ceramic bezel could have also been removed from the
mixer valve but Mira’s original specification requirements did not allow for this to happen. Finally, the original polybag packaging was
adapted to reduce the process time and now takes the form of a branded Mira card housing. Boothroyd software evaluations highlighted
an increase in efficiency of the assembly process of 31.36% totaling 12.44%, up from 9.47%. The assembly time savings for the redesign
totaled 39.74%, totaling 112.57 seconds, down from 186.81 seconds.
Mira provided feedback on the first redesign iteration, which suggested additional changes should be made to make the DFA process more
realistic. The changes included increasing the male snap fit sizes to increase durability. A bearing underneath the virtue shroud was added
to prevent chrome-to-chrome contact with the classic body assembly. The male snap fit material was changed to acetal and solvent
bonded to the glass filled nylon base. Finally, the ceramic bezel was changed to polymer to allow it to be snap fitted into the handle recess.
ORIGINAL REDESIGN
After incorporating these additional changes into a second redesign iteration, the time and cost of the assembly process would increase
marginally but the assembly process would become more viable. Total Parts Total Parts
15 60%
DECREASE
6
The aim for the project was to design Mira’s ‘Heritage’ Virtue mixer valve for better assemblability. This aim was met through a combination
of design changes and iterations. The aim stated at the start of the project was accomplished through the completion of the six objectives: Sub-Assemblies Sub-Assemblies
Design Efficiency 3 100%

DECREASE
0 Design Efficiency
Objective 1. Assess the product for ease of manufacture and assembly.

Achieved by analysing the physical product and carrying out an initial Boothroyd software evaluation on the components and operations 9.47 Separate
Operations
16 31.25%
Separate
Operations
11
12.44
in the assembly process. DECREASE
Assembly Assembly
Objective 2. Identify opportunities for improvements in product and process design. Time Time
Achieved by visual inspection and analysis of the product as well as redesign suggestions from the Boothroyd simulation.
186.81s
39.74%DECREASE
112.57s
Objective 3. Propose alternatives for product and process design.

Achieved through the completion of redesign and blue skies designs. A down selection of ideas was completed to identify the design that
conformed to Mira’s specifications whilst increasing assemblability. 31.36
INCREASE IN DESIGN EFFICIENCY
Objective 4. Compare the proposal to the original design.

Achieved by comparing the Boothroyd software analysis of the redesign to the original. Reductions in time were identified.
Objective 5. Assess the technical and commercial feasibility of the proposed design.
Positive results after assessment against DFS best practise guides, Mira feedback, 3D printing and testing and analysis against the PDS.
Objective 6. Recommend resultant product, process and tooling changes.

Positive reduction in part count from 14 to 5, efficiency increased by 31.36% and time saving of 39.74% when compared to original product.
Mira gave positive feedback on the product redesigns. However, Mira could not implement the product changes as they would have to
occur in the ‘Design Phase’ and not post production. Mira could look to incorporate the design changes in future products. Overall the
project was considered a success.

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18WSC400 ELECTIVE - DESIGN FOR ASSEMBLY

COURSEWORK ASSIGNMENT NO. 3

B418539 - Abhi Ghavalkar (C)

INTRODUCTION, AIMS & OBJECTIVES

1 - ORIGINAL PRODUCT ASSESSMENT

6 - PRODUCT & PROCESS CHANGES

EVALUATION AGAINST AIMS & CONCLUSION

The portfolio is structured based on the six objectives outlined above.

Excerpts from PDS Process

Target Market It is assumed that a top-down approach has been applied.

LIST OF COMPONENTS M4 X 40 CAP SKT PATCHED

Assembly CAD Diameter (mm) / Height Weight

1E 8 1 BEARING Acetal 360 180 540 18.9 6.8 N/A 1.0

Assembly CAD Diameter (mm) / Height Weight

1J 9 1 WASHER Nylon 360 0 360 12.9 3.4 N/A 1.0

Assembly CAD Diameter (mm) / Height Weight

1M 12 1 STICKY PAD Adhesive 0 0 0 5.6 5.6 1.2 1.0

1S N/A 1 POLYBAG 10 X 12 INCHES 360 0 360 ~160.0 ~240.0 N/A N/A

MIRA VIRTUE ERD Out of Total Out of 14 Parts Out of 12 Parts

14+1 Parts being inves�gated (incl. packaging)

1 Load Body into fixture 4 Screw down headnut

13 Locate Handle Bottom on 14 Push down Shroud 15 Locate Handle in to Hub

18 Locate Bezel Retainer in fixture

19 Insert Bezel Spring into Bezel Retainer

Aid Image Use

Assembly Fixture 24269 Pick up Body Assembly and place in fixture

Project Summary / Objectives 2 - Design

User Trim Spokes to be at 45° when Handle

Text to be debossed into Shroud Artwork to be transfer positioned

SUPPLIERS OF INDIVIDUAL COMPONENTS

ALL OTHER PARTS

POTENTIAL DESIGN SOLUTIONS:

1) Efforts will be made to eliminate adhesives and fasteners.

Mira Valve Redesign Ideas

BETTER THAN ORIGINAL

WORSE THAN ORIGINAL

Minimize Part Count 10 + + + + +

Self Locating Features 6 = = + + +

Self Fastening Features 8 = = + = =

Design for Retrieval,

Mira Valve Blue Skies Concepts

BETTER THAN ORIGINAL

WORSE THAN ORIGINAL

Minimize Part Count 10

Self Locating Features 6

Self Fastening Features 8

Encourage a Modular Design 5

False bolt head incorporated

Stops added in groove

O-Ring over-moulded into inner diameter of Shroud

NEW VIRTUE SHROUD NEW CLIPS ON THERMSTREAM

Snap fit feature that

Stops engage with teeth/clips in

The Ceramic Bezel will no longer need to be removed for disassembly.

It is a one-time snap fit component.

CLASSIC BODY ASSY

1 Load Body into fixture

2 Grease inside of Body

3 Insert Thermstream into Body

5 Shut off cartridge (Thermstream)

6 Locate into fixture & test

7 Place body into assembly fixture