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Design For Manufacturing and Assembly

DFMA is a proactive and concurrent manufacturing aspects

design

process that allows for early consideration of

The purpose is to generate an environment where a cross-functional team works together to optimize the manufacturing design for cost effective

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benefits
Tangible

Shortened Development Time Development Costs a smooth transition to production

Reduced

Enhances Reduced

parts count assembly processes Quality

Simplified Improved Reduced Intangible Improved

manufacturing costs

team

communication within entire design

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DFMA Principles
Minimize

the number of parts

Standardize Avoid Use Use

difficult components

modular subassemblies multifunctional parts reorientation self-locating features special tooling/test equipment accessibility operations & process steps

Minimize Use

Avoid

Provide

Minimize

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Introduction
What is DFM?
DFM is product design considering manufacturing requirements DFM is the first step in which a team approach is taken to develop the product DFM is an umbrella which covers a variety of tools and techniques to accomplish a manufacturable product

Why DFM?
Lower development cost Shorter development time Faster manufacturing start of build Lower assembly and test costs

Introduction
How do all the pieces fit together?
The objective of DFM is to identify product concepts that are easy to manufacture Focus on component design for ease of manufacture and assembly Integrate manufacturing to ensure the best match of needs and requirements. DFM in industry is typically divided into 2 main activities: vA team which will be responsible for the product

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Introduction
(DFM) is the general engineering art of designing products in such a way that they are easy to manufacture. The basic idea exists in almost all engineering disciplines, but of course the details differ widely depending on the manufacturing technology. This design practice not only focuses on the design aspect of a part but also on the producibility. In simple language it means relative ease to manufacture a product, part or assembly.

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DESIGN for manufacturability (DFM) is the process of proactively designing products to: a) optimize all the manufacturing functions:

fabrication, assembly test, procurement, shipping, service, and repair; b) assure the best compliance, safety, cost, quality, reliability, regulatory time to market, and customer

satisfaction; and c) ensure that lack of manufacturability styling, new doesnt product

compromise

functionality,

DFM Method

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DFM Method
Estimate Reduce Reduce Reduce

the manufacturing costs.

the costs of components. the costs of assembly. the costs of supporting production. the impact of DFM decisions on other

Consider

factors.

Estimate the Manufacturing Costs

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Manufacturing Costs Defined

Sum

of all the expenditures for the inputs of the

system (i.e. purchased components, energy, raw materials, etc.) and for disposal of the wastes produced by the system

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Elements of the Manufacturing Cost of a Product

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DFA Systems
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

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Introduction

The aim of design for assembly (DFA) is to simplify the product so that the cost of assembly is reduced. DFA recognizes the need to analyze 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 assimilability concurrently."

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TYPES AND CHARACTERISTICS OF ASSEMBLY METHODS Manual Assembly

In manual assembly, the operations are carried out manually with or without the aid of simple, general purpose tools like screwdrivers and pliers. Individual workbench components either are transferred or by to the

manually

employing

mechanical equipment such as parts feeds or transfer

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TYPES AND CHARACTERISTICS OF ASSEMBLY METHODS Automatic Assembly Using Robots / Robotic Assembly: Production volume is higher than that of a manual

assembly system but lower than that of an automatic assembly system (Fixed automation). Common forms of Robotic Assembly:

Comparison of Assembly Methods Manual assembly requires the least capital investment followed by the two simplest forms of robotic assembly.

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TYPES AND CHARACTERISTICS OF ASSEMBLY METHODS Automatic Assembly Using Robots / Robotic Assembly: Production volume is higher than that of a manual

assembly system but lower than that of an automatic assembly system (Fixed automation). Common forms of Robotic Assembly:

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Design Guidelines for Manual Assembly the following guidelines depend on the skill of the worker:

eliminate the need for workers to make decisions or adjustments.

ensure accessibility and visibility. eliminate the need for assembly tools and gauges (i.e. prefer self-locating parts).

minimise the number of different parts - use "standard" parts. avoid or minimise part orientation during assembly (i.e. prefer symmetrical parts).

prefer easily handled parts that do not confuse within one

Design Guidelines for Automation

The main different here is that assembly is performed by machines instead of by humans.

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reduce the number of different components by considering

does the part move relative to other parts? must the part be isolated from other parts (electrical, vibration, etc.)? must the part be separate to allow assembly (cover plates, etc.)?

use self-aligning and self-locating features avoid screws/bolts use standard components and materials. avoid tangling or nesting parts. avoid flexible and fragile parts. avoid parts that require orientation.

Design Guidelines for Robotic Assembly

design

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the part so that it is compatible with the robot's end effector. the part so that it can be fed in the proper orientation.

design

Basic DFA Guidelines

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Minimise part count by incorporating multiple functions into single parts

Modularize multiple parts into single subassemblies Assemble in open space, not in confined spaces; never bury important components

Make parts such that it is easy to identify how they should be oriented for insertion

Prefer self-locating parts Standardise to reduce part variety Maximise part symmetry Design in geometric or weight polar properties if nonsymmetric

Basic DFA Guidelines

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Prevent nesting of parts; prefer stacked assemblies Provide orienting features on nonsymmetries Design the mating features for easy insertion Provide alignment features Insert new parts into an assembly from above Eliminate re-orientation of both parts and assemblies Eliminate fasteners Place fasteners away from obstructions; design in fastener access Deep channels should be sufficiently wide to provide access to fastening tools; eliminate channels if possible

Provide flats for uniform fastening and fastening ease

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Mass Customization
Click to edit Master subtitle style

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Introduction
Mass

productionofgoodswith the

differing use of

individualspecificationsthrough numberof different

components that may be assembled in a configurations. Mass customization is a cost-efficient way ofoffering some of thebenefitsof customization.

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Mass Customization
We

define mass customization as providing

products and services which meet the needs of each individual customer with regard to certain product features with near mass production efficiency.

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Mass Customization
Mass Customization to Stan is an academic in his

term, book

attributed

Davis

Future Perfect where he writes about mass customization, the production and distribution of

customized goods and services on a mass basis.

Types of Mass Customization (1)

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The Four Faces of Mass Customization

1. Collaborative Customization:

Consumer and producer engage in a conversation to determine customer requirements

Computers, clothing and footwear, furniture, some services

2.

Adaptive Customization:

Product is designed so that users can alter it themselves to fit unique requirements on different occasions

Types of Mass Customization (2)

3.

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Cosmetic Customization:

Product is unique in appearance only Customers chosen text or image on T-shirts, mouse mats, baseball caps, mugs etc.

Also called Personalization

4.

Transparent Customization:

Producer provides customized product without consumer being necessarily being aware that it has been customized

Can be used when consumers needs are

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True Mass Customization

True

Mass Customization requires:

System

for customer to specify requirements easily e.g. online ordering, call center manufacturing systems
Enable economies of scope (keep cost and price low)

Advanced

Build-to-order

approach

product is not made until order is received

Minimum
31 October 2005

order quantity of one

Copyright MadeForOne.com 2005

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Advantages of MC
Customer Does

has control over product

not have to pay for features he/she does not want (computers etc.) does not have finished product inventory better use of working capital for company to differentiate product out economic fluctuations

Company Easier Levels

When slowdown occurs, less backlog of inventory Prices do not have to be cut as much Therefore, less likelihood of recession

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What Mass Customization Isnt

Massive Product Variety Customer has Choice but not Control;

E.g. Personalize your cellphone with any of our 2000 skins

Advanced ordering system linked to craft production;

Example: Well known snowboard maker customer can specify exact requirements online but boards are hand-made

Personalization or mass customization of Marketing:

Use of knowledge about customer to personalize marketing of standard products. Data gathered from loyalty schemes, etc.

Customized products with minimum quantities

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Examples of Mass Customization

Dell

Build to order computers not manufacture (modular components) MC sometimes associated with higher prices but Dell cheaper than most Massive efficiency of supply chain management 2004 in Dell Time - Fast Company, Nov.

Assembly,

Why?

Living

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Examples of Mass Customization

Clothing
NikeID,

and Footwear
MiAdidas, Otabo Shoes, Vans

Bivolino

(shirts), U-Jeans, Lands End, Target, Tommy Hilfiger and footwear very suited to MC due to each person being unique in size and shape

Clothing

Sports

Equipment
(treadmills)

Nautilus

Industrial
Kingspan

equipment, construction
insulated roof and wall panels,

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Product-Process Matrix
PRODUCT STRUCTURE
VERY LOW VOLUMES VERY HIGH VOLUMES LOW VOLUMES Many Products HIGH VOLUMES Few Products

PROCESS STRUCTURE
JUMBLED FLOW (Job Shop)

LOW STANDARDIZATION One-of-a-kind Products

HIGH STANDARDIZATION Commodity Products

DISCONNECTED LINE FLOW (Batch Flow)

CONNECTED LINE FLOW (Machine or Worker paced)

CONTINUOUS FLOW

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Product-Process Matrix

Movement along the Diagonal

Rarely does a company move directly from one cell on the diagonal to another. Usually, due to a internal decision or a external factor, a company follows one of two paths:
the red path (over & down)

OR the green path below (down & over).

P O U TS R C U E R D C T U T R
V R H HV L M S E Y IG O U E L WV LU E O O M S M ny P uc a rod ts H HV L M S IG O U E F P ew rodu cts H HS N A D A N IG TA D R IZ TIO C m ity P ucts om od rod

V R LO V LU E E Y W O M S

P O E S R C S SR CU E T U T R
JU B E F W M L D LO (J S p ob ho )

L WS N A D A N O TA D R IZ TIO O -o -kind P uc ne f-a rod ts

D C N E T DLIN F O IS O N C E E L W (B atch F w lo )

C N E TE L E F O O N C D IN L W (M in o W rker p ed ach e r o ac )

C N U U FO O TIN O S L W

37 37

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Product-Process Matrix

Movement along the Diagonal

(continued)

Which path red or green can be described as Conservative, puts pressure on Manufacturing, and results in Opportunity Costs? Which path red or green can be described as risky, puts pressure on Marketing/Sales, and results in out-of-pocket costs?
P O U TS R C U E R D C T U T R
V R LO V LU E E Y W O M S V R H HV L M S E Y IG O U E L WV LU E O O M S M ny P uc a rod ts H HV L M S IG O U E F P ew rodu cts H HS N A D A N IG TA D R IZ TIO C m ity P ucts om od rod

P O E S R C S SR CU E T U T R
JU B E F W M L D LO (J S p ob ho )

L WS N A D A N O TA D R IZ TIO O -o -kind P uc ne f-a rod ts

D C N E T DLIN F O IS O N C E E L W (B atch F w lo )

C N E TE L E F O O N C D IN L W (M in o W rker p ed ach e r o ac )

C N U U FO O TIN O S L W

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Service Process Matrix

DEGREE OF CONTACT WITH, AND CUSTOMIZATION FOR, THE CONSUMER Low The Service Factory Low DEGREE OF LABOR INTENSITY High High The Service Shop

Mass Service

Professional Service

39 39