DFA of Max Co.

Vaimo HD-11FL Stapler

Design for Manufacture & Assembly Prof: Dr. Ariffin Bin Abdul Razak FKM UTM, JB

Group Members
Aleem Ullah Adamu Bashir Gidado
Just because you can make something doesnt mean you can manufacture it

Introduction:
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.

Objectives
To study the original product design based on DFA concept.

To make improvements in the original design in terms of cost, assembly time, fastening methods, and number of components. To determine design efficiency of the product for original and new design.

Product to be Studied:
A stapler is a mechanical device that joins sheets of paper or similar material by driving a thin metal staple through the sheets and folding the ends. Staplers are widely used in government, business, offices, and schools. In this project DFA will be carried out on Japanese made Max Co. Vaimo HD-11FL Stapler stapler. It enables stapling 2 to 35 sheets (80gsm Paper) with ease using a single hand. Unique twin lever mechanism cuts stapling effort by 50%, its Compact and ergonomic styling provides comfortable stapling.

Product Description:
Old Design: Total No. of Parts = 35 Total No. of Different Parts = 33 New Design: Total No. of Parts = 19 Total No. of Different Parts = 19

No.

Image

Part Name

Function
Houses the anvil, metallic base spring & anvil plastic support

Material

Metallic Base

Steel

Anvil Plastic Support

Supports the anvil on the metallic base

Plastic

Product Description: Cont.

No. Image Part Name Function Material

Anvil

Bends the staples to the desired shape

Steel

Anvil Spring

Provides damping motion to the anvil/anvil plastic support

Steel

Metallic Base Spring

Retrieves bottom staple guide once the stapling force is released

Steel

Product Description: Cont.

No. Image Part Name Function Houses and forwards the stapes towards the hammering position Material

Bottom Staple Guide

Steel

Pusher Rod

Guides the pusher head

Steel

Pusher Head

Pushes the hammer towards hammering location

Plastic

Product Description: Cont.

No. Image Part Name Function Aids in retrieving the pusher head for loading/unloading of staples Material

Pusher Head Retriever

Plastic

10

Pusher Spring

Provides the force to the pusher head to push the staples

Steel

11

Pusher Rod Cap

Provides the need for a critical force before staples are ejected from the hammering position

Steel

Product Description: Cont.

No. Image Part Name Function Connects the bottom staple guide to the metallic base. Also provides a relative motion between them. Material

12

Lower Pin

Steel

13

Upper Arm

Encompasses the hammer. Presses the upper staple guide.

Steel

14

Rear Pin

Connects the metallic base, bottom staple guide and the upper arm. Allows a relative motion between the three major parts.

Steel

Product Description: Cont.

No. Image Part Name Function Prevents the staples/pusher head from ejection from the bottom staple guide. Material

15

Upper Staple Guide

Steel

16

Upper Arm Casing

It encloses the upper arm. Allows the top plastic casing to snap fit to it.

Steel

17

Upper Pin

It connects the upper arm to the upper arm casing

Steel

Product Description: Cont.

No. Image Part Name Function Covers the upper arm casing. Prevents the upper pin from falling out. Provides good comfort & aesthetic value. Supports the anvil. Covers the metallic base. Provides good comfort & aesthetic value. Material

18

Top Plastic Casing

Plastic

19

Bottom Plastic Casing

Plastic

Assembly Sequence: (Old Design)

Product Tree Structure: (Old)

Main Body
Metallic Base Bottom Staple Guide Casing Upper Arm
Upper Staple Guide

Upper Arm Casing

Upper Pin

Staple Guide Joining Spring

Plastic Guide

Slide Guide

Lower Pin

Actuator Pusher Head Rear Pin Metallic Base Spring Bottom Plastic Casing Anvil Upper Plastic Support Anvil Spring Guide Anvil Anvil Spring Pusher Rod Anvil Upper Plastic Spring Large Pusher Spring Anvil Lower Plastic Support Small Pusher Spring

UAC Cover Spring

Upper Leaf Spring

Upper Arm Casing Cover

Top Plastic Casing

Anvil Lower Plastic Support Spring Small Plastic Clip

Pusher Slides

Pusher Rod Cap

Pusher Head Retriever

Parts Eliminated/Integrated into others

DFA Worksheet: (Old)

Unchanged
No. of times the operation is carried out consequently Two-Digit manual handling code Two-digit manual insertion code Manual Handling time per part Manual insertion time per part

Modified
Figures for theoretical minimum parts estimation

Eliminated

Operation time (sec) (2)x[(4)+(6)]

Operation cost 0.001499x(7)

Part #

Name Of Assembly

1 2 3 4 5 6 7

1 1 1 1 1 1 1

30 30 40 01 30 20 03

1.95 1.95 3.6 1.43 1.95 1.8 1.69

00 30 30 00 30 06 06

1.5 2 2 1.5 2 5.5 5.5

3.45 3.95 5.6 2.93 3.95 7.3 7.19

0.0052 0.0059 0.0084 0.0044 0.0059 0.0109 0.0108

1 0 0 0 1 1 0

Metallic Base Anvil Lower Plastic Support Anvil Lower Plastic Support Spring Anvil Upper Plastic Support Spring Anvil Upper Plastic Support Anvil Anvil Spring

DFA Worksheet: (Old) Cont.

8 9 10 11 12 13 14 15 16 17 18 19 1 1 1 1 1 1 1 1 1 1 1 1 31 31 00 30 30 40 30 03 30 13 00 00 2.25 2.25 1.13 1.95 1.95 3.6 1.95 1.69 1.95 2.06 1.13 1.13 00 30 00 00 00 30 30 00 00 30 00 00 1.5 2 1.5 1.5 1.5 2 2 1.5 1.5 2 1.5 1.5 3.75 4.25 2.63 3.45 3.45 5.6 3.95 3.19 2.925 4.06 2.63 2.63 0.0056 0.0064 0.0039 0.0052 0.0052 0.0084 0.0059 0.0048 0.0044 0.0061 0.0039 0.0039 0 0 1 1 0 0 0 1 1 1 0 0 Anvil Spring Guide Small Plastic Clip Metallic Base Spring Bottom Staple Guide Casing Bottom Staple Slide Guide Staple Guide/Casing Joining Spring Plastic Support For Metallic Base Spring Pusher Rod Pusher Head Pusher Head Retriever Small Pusher Spring Large Pusher Spring

20
21

2
2

72
30

5.85
1.95

08
31

6.5
5

24.7
13.9

0.037
0.0208

0
0

Pusher Head Slides

Pusher Rod Caps

22

03

1.69

31

6.69

0.0100

Lower Pin

DFA Worksheet: (Old) Cont.

23 24 25 26 27 28 29 30 1 1 1 1 1 1 1 1 30 30 00 30 30 30 00 33 1.95 1.95 1.13 1.95 1.95 1.95 1.13 2.51 06 35 30 00 30 30 30 30 5.5 5 2 1.5 2 2 2 2 7.45 6.95 3.13 3.45 3.95 3.95 3.13 4.51 0.0112 0.0104 0.0047 0.0052 0.0059 0.0059 0.0046 0.0068 1 0 1 0 1 1 0 0 Upper Arm Upper leaf spring Rear Pin Actuator Upper staple Guide Upper arm casing Upper pin UAC Cover Spring

31
32 33

1
1 1

30
30 30

1.95
1.95 1.95

00
30 30

1.5
2 2

3.45
3.95 3.95 170.045

0.0052
0.0142 0.0142 0.2571

0
0 0 12

Upper Arm Casing Cover

Top plastic casing Bottom plastic casing Design efficiency=21.17%

Labor Rate = 950/(22x8x60x60) = 0.001499 RM Per Second Design Efficiency = 3 x NM/TM Our Assembly Time: (387 + 411+ 398)/3 = 398.6 Sec

Design Improvements:
1. Combination of the 4 parts of bottom staple guide to one

Weakness:
Difficult to assemble the spring

Solution:
Combine the 4 parts to make 1 part

Assembly time for the 4 parts: 3.45+3.45+3.95+5.6= 16.45 sec

Assembly time for the new bottom staple guide: 3.45sec (Time reduced = 13 sec) (Cost Cut=0.0195 RM)

Design Improvements:
2. Modifying the anvil upper plastic support while eliminating the anvil lower plastic support

Weakness:
Long handling/assembly time

Solution:
Combine the upper plastic with the lower plastic support

Assembly time for the 5 components: 3.95 + 3.95+5.6+2.93+4.25 = 20.68 sec

Assembly time for the new anvil plastic support: 3.95 sec (Time reduced = 16.72 sec) (Cost Cut=0.0251 RM)

Design Improvements:
3. Combining the upper arm with the upper leaf spring and hammer head

Weakness:
Requires riveting which is time consuming

Solution:
Combine to form a single component

Assembly time for the three parts: 7.45+6.95+3.45= 17.85 sec

Assembly time for the new upper arm: 7.45sec (Time reduced = 10.4 sec) (Cost Cut=0.0156 RM)

Design Improvements:
4. Eliminating 1 pusher spring

Weakness:
1. One spring must be inserted in the other spring 2. Time consuming

Solution:
Use only one spring

Assembly time for the two springs: 2.63+2.63= 5.26 sec

Assembly time: 2.63 sec (Time reduced = 2.63 sec) (Cost Cut=0.0039 RM)

Design Improvements:
5. Eliminating 1 pusher rod cap.

Weakness:
1. One of the pusher rod caps is inserted in the other 2. Time consuming

Solution:
Use only one pusher rod cap

Assembly time for the two pusher rod caps: 13.9 sec

Assembly time for the pusher rod cap: 6.95 sec (Cost Cut=6.95 RM)

Design Improvements:
6. Combining the pusher head with the pusher slides

Weakness:
Inserting the pusher slides is time consuming and difficult.

Solution:
Combine the pusher head with the pusher slides

Assembly time of the three parts above: 12.35+12.35+2.925= 27.625 sec

Assembly time of the new pusher head: 2.925 sec (Time reduced = 24.7 sec) (Cost Cut=0.037 RM)

Design Improvements:
7. Modification of the metallic base

Weakness:
The anvil spring passes through a hole in the metallic base. So, it requires holding during subsequent operation

Solution:
Provide a support for the anvil spring and eliminate the anvil spring guide

Assembly time for the 3 parts above: 3.45+7.19+3.75= 14.39 sec

Change the anvil spring with a bigger diameter spring Assembly time for the new anvil spring and metallic base: 3.45+2.63= 6.08 sec (Time reduced = 8.31 sec) (Cost Cut=0.0124 RM)

Design Improvements:
8. Combining the top plastic casing with the UAC cover

Weakness:
Assembly of UAC cover is time consuming and sensitive.

Solution:
Combine the top plastic casing with the UAC cover and eliminate the UAC cover spring

Assembly time for the 3 components above: 3.95+3.45+4.15= 11.55 sec

Assembly time for the new top plastic casing: 3.95 sec (Time reduced = 7.6 sec) (Cost Cut=0.0114 RM)

Product Tree Structure: (New)

Main Body

Metallic Base

Bottom Staple Guide

Upper Arm

Upper Arm Casing

Bottom Plastic Casing

Pusher Head

Upper Staple Guide

Upper Pin

Rear Pin

Pusher Rod

Top Plastic Casing

Metallic Base Spring

Pusher Spring

Anvil Plastic Support

Pusher Rod Cap

Anvil

Pusher Head Retriever

Anvil Spring

Lower Pin

DFA Worksheet: (New)

Two-Digit manual handling code Two-digit manual insertion code Figures for theoretical minimum parts estimation Manual Handling time per part Manual insertion time per part No. of times the operation is carried out consequently Operation time (sec) (2)x[(4)+(6)]

Operation cost 0.001499x(7)

Part #

Name Of Assembly

1 2 3 4

1 1 1 1

30 30 20 00

1.95 1.95 1.8 1.13

00 30 00 00

1.5 2 1.5 1.5

3.45 3.95 3.30 2.63

0.0052 0.0059 0.0049 0.0039

1 1 1 0

Metallic Base Anvil Plastic Support Anvil Anvil Spring

5 6 7

1 1 1

00 30 03

1.13 1.95 1.69

00 00 00

1.5 1.5 1.5

2.63 3.45 3.19

0.0039 0.0052 0.0048

1 1 1

Metallic Base Spring Bottom Staple Guide Pusher Rod

DFA Worksheet: (New) Cont.

8
9 10 11 12 13 14

1
1 1 1 1 1 1

30
13 00 30 03 30 00

1.95
2.06 1.13 1.95 1.69 1.95 1.13

00
30 00 31 31 06 30

1.5
2 1.5 5 5 5.5 2

2.925
4.06 2.63 6.95 6.69 7.45 3.13

0.0044
0.0061 0.0039 0.0104 0.0100 0.0112 0.0047

1
1 0 0 0 1 1

Pusher Head
Pusher Head Retriever Large Pusher Spring Pusher Rod Caps Lower Pin Upper Arm Rear Pin

15
16 17 18 19

1
1 1 1 1

30
30 00 30 30

1.95
1.95 1.13 1.95 1.95

30
30 30 30 30

2
2 2 2 2

3.95
3.95 3.13 3.95 3.95 75.365

0.0059
0.0059 0.0046 0.0059 0.0059 0.1068

1
1 0 0 0 12

Upper staple Guide

Upper arm casing Upper pin Top plastic casing Bottom plastic casing Design efficiency=47.8%

Labor Rate = 950/(22x8x60x60) = 0.001499 RM Per Second Design Efficiency = 3 x NM/TM

Comparison Between Old & New Design:

Old Design No. of Different Components 33 New Design 19 Improvement 42.4% Reduction

Assembly Time

170.045 Sec

75.365

55.7% Reduction

Assembly Cost

0.2571

0.1068

58.5% Reduction Increased By 26.6%

(125.8% Improvement)

Design Efficiency
Assembly Levels

21.17%
3

47.8%
2

33% Improvement

Labor Rate = 950 RM Per Month OR 0.001499 RM Per Second

Conclusion:
From DFA method, we reduced the number of parts, assembly time and cost by BoothroydDewhurst method. We eliminated certain springs, while keeping their functionality. Parts were redesigned to integrate other parts hence reducing the total number of parts, and improve ease of assembly and its cost. 4 major and 4 minor improvements were made.

Thank You !