DIGITAL ASSIGNMENT 3

PRODUCT DESIGN FOR

MANUFACTURING

Name: Prajari Ghosh

Reg. no: 17BME1290

1)
The initial design of the power saw had 41 parts and an estimated
Assembly time of 6.37min.
The redesign had 29 parts for a 29%
Reduction in part count, and an estimated assembly time of 2.58min for a 59%
Reduction in assembly time. The outcome of further analyses was a more than
50% savings in assembly time, a significant reduction in parts count and an
Anticipated improvement in product performance.

DFA INDEX OF INITIAL DESIGN=(Nmin*tm)/tma

=(41*3)/382.2=0.3218

DFA INDEX OF REDISIGN= (29*3)/154.8=0.562

2)

Quality Function Deployment (QFD)

Definition: Quality function deployment is a systematic approach of specifying the
customer needs and desires, rating them in terms of priority and designing the quality
products and process to serve these requirements, through proper planning.

QFD is a process of bridging the gap between where we stand and what we aim at, by
providing target values and competitive analysis.
This tool is widely applied in case of:

 Derivative products which are familiar but launched in a new market

 Products which are casual but have been introduced with a twist;
 Next-generation products which have a new concept and started in an established
market.

However, QFD is not applicable in case of products which have a new concept and
introduced in a new market (i.e., first of its kind products). This is because of insufficient
information or consumer data.

Content: Quality Function Deployment (QFD)

1. Process
1. Product Planning
1. House of Quality
2. Design Deployment
3. Process Planning
4. Production Planning
2. House of Quality Example
3. Benefits
4. Disadvantages
5. Conclusion
QFD Process

A quality function deployment emphasizes on product and process design. It involves the
following four phases:

House of Quality HOQ

House of quality is a matrix which is the basis of product planning, and its diagram looks
like a house. It is a realistic approach which analyzes the consumer desires and matches it
with the technical attributes of a product, to optimally fulfil these requirements by
utilizing the resources available with the organization.

Given below is the house of quality of XYZ helmets:

 1. The middle part of the matric presents the relationship between customer needs and
the technical specifications of the product.
2. The roof of the house shows the correlation between the technical specifications.
3. The bottom of the matrix depicts the importance of each technical specification
when compared to consumer needs.
4. The columns below the importance (%) shows the ratings in terms of fulfilment of
the individual technical requirement by each company.
5. The right side of the matrix provides a comparative study by listing the customer
preference ratings for the brands in terms of individual requirements.

From the above diagram, we can quickly figure out that:

 The company has met the safety requirements of the customers to the fullest.
However, it needs to work more on the styling of its products.
 Also, XYZ helmet’s outer shell is considered to be of premium quality and robust
build. But, the company has to control its cost of production.
 Moreover, the company has the edge over the other brands in terms of safety, price
and light weightedness.
 The company has to pay attention to the comfort level of the helmets still to
improve consumer satisfaction.

3)

Figure 1

Digit 1: The total length of the part is 30, overall diameter 10, A/B = 3, A/C=5 (code 6)

Digit2: External shape - aNON rotational part (code 4)

Digit3: Internal shape elements principle bores (code 6)

Digit 4: plane machine surfaces (code 1)

Digit 5: auxiliary holes (code 1)

Primary code:64611

Digit 6: dimensions (code 1)

Digit 7: Material-Mildsteel (code 2)

Digit 8: Raw material form (code 2)

Digit 9: No accuracy (code 0)

Supplementary code:1220

Figure 2

Digit 1: The total length of the part is 7, overall diameter 20, L/D=0.35 (code 0)
Digit 2: External shape –FUNCTIONAL GROOVE (code 3)

Digit 3: No hole (code 0)

Digit 4: External groove for slot (code 3)

Digit 5: No auxiliary holes (code 0)

Primary code:03030

Digit 6: dimensions (code 0)

Digit 7: Material-steel heat treated (code 4)

Digit 8: Raw material form-Bar (code 2)

Digit 9: No accuracy (code 0)

Supplementary code:0420

Figure 3

Digit 1: The total length of the part is 30, overall diameter 12, L/D<3 (code 1)

Digit 2: External shape - a rotational part (code 5)

Digit 3: No shape elements (code 1)

Digit 4: No surface machining (code 0)

Digit 5: No auxiliary holes (code 0)

Primary code:15100

Digit 6: dimensions (code 0)

Digit 7: Material-hard steel (code 3)

Digit 8: Raw material form-round bar (code 1)

Digit 9: No accuracy (code 0)

Supplementary code:0310