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A SEMINAR ONDESIGN FOR MANUFACTURING
ASSEMBLY PROCESS
SUBMITTED BYD.SANTOSH KUMAR14481D1506
• Design for manufacturing (DFM) is design based on minimizing the cost of production and/or time to market for a product, while maintaining an appropriate level of quality. The strategy in DFM involves minimizing the number of parts in a product and selecting the appropriate manufacturing process.
Design for Manufacturing
DIFFERENCES:
Design for Assembly (DFA)
• concerned only with reducing product assembly cost– minimizes number of assembly operations
– individual parts tend to be more complex in design
Design for Manufacturing (DFM)
• concerned with reducing overall part production cost– minimizes complexity of manufacturing operations
– uses common datum features and primary axes
DESIGN FOR ASSEMBLY
“A PROCESS FOR IMPROVING PRODUCT DESIGN FOR EASY LOW-COST ASSEMBLY, FOCUSING ON FUNCTIONALITY AND ON ASSEMBLABLITY CONCURRENTLY.”
-VINCENT CHAN &FILIPPO.
Design of components taking into account how they will be assembled together to ensure that assembly costs are minimized.
DFA is the method of design of the product for ease of assembly
Manual
Most flexible & Most expensive
Skill of workers effects assembly times
Hard Automation
Custom tooling – only make one product
Soft Automation
Robots
Types of Assembly
Concept Design
Design for
Assembly
Design for
Manufacturing
Detailed Design
Optimize Design for
Part Count and
Assembly
Optimize Design for
Production Readiness
Sequence of Analysis
Product Information: functional requirements
Functional analysis
Identify parts that can be standardized
Determine part count efficiencies
Step 2
Step 1
Analyze data for new design
Step 3
Identify handling (grasp & orientation) opportunitiesStep 4
Identify insertion (locate & secure) opportunitiesStep 5
Step 6 Identify opportunities to reduce secondary operations
Identify quality (mistake proofing) opportunities
Benchmark when possible
Determine your practical part count
Step 7
DFA Process
1. Reduce number of parts
2. Reduce number of different parts - Standardize parts
3. Simplification of assembly
4. Reduction number of processes
5. Less fasteners especially screws & bolts
6. Design parts with self-locating features
7. Design parts with self-fastening features.
8. Minimize reorientation of parts during assembly
9. Ensure access & visibility
10. Easy part handling
11. Assemble from top
12. Reduce locating/alignment operations – manual/time consuming
DFA Guidelines
Proposed design of a motor drive assembly
REDUCE PARTS:
The following change could easily be made:
the powder metal bushings are unnecessary because the part can be machined from an alternative material with the right frictional characteristics, such as Nylon
The following are difficult to justify:
separate stand-offs
end plate
cover
the six screws
We started with this.
At the end of the changes due to DFMA are:
STANDARDIZED PARTS:
Easier = faster
Less opportunity for mistakes
Easier to automate
Simplification of assembly:
• Less steps = faster
• Less material handling = less damage
• Less operations = less opportunity for defects
Reducing Number of Processes
Less Fasteners especially screws & bolts
Left to right: simplest, low cost to most parts hardest to assembly
SELF LOCKING AND SELF-FASTENING
SELF LOCATING PARTS
Asymmetric Part Symmetry of a part
makes assembly easier
Symmetry eliminates reorientation
1. Critical orientation – obvious – see & fit
2. Non-critical orientation – fit in any direction
Rivet
Eliminate Secondary Operations
Screwing, drilling, twisting, riveting, bending Welding, soldering, gluing, Painting, lubricating
ENSURE ACCESS & VISIBILITY
Easy part handling
size slipperiness
sharpness flexibility
Size WeightShapeSharp edgesStickyTangled & Nested
Eliminate Tangling/Nesting
Assemble from Top
Insertion from the top is preferred.
Reduce locating/alignment operations –manual/time consuming
Any Queries