Design for manufacturing and assembly case study pdf

Standridge manufacturing and quantitative analysis performed using tools such as mathematical optimization and discrete event simulation. There is a need for indepth study of the architectures for dfma systems in order that the latest software and knowledgebased techniques may be used to deliver the dfma systems of tomorrow. The design freedom suggests optimal solutions in the assembly time minimization problem regardless costs and issues about materials and manufacturing processes selection. Design for manufacturing and assembly dfma 5 case study. The overall goal is to reduce manufacturing and assembly costs while also quantifying the improvements. The current project addresses the productivity improvement of a manual assembly line by making use of operations analysis in the framework of lean production. In many cases the main realization of this is design for manufacture and assembly dfma. Utilizing dfm to support the development of a new generation of ups. Paper open access design for manufacture and assembly. Computer aided design and manufacturing is an ideal textbook for undergraduate and graduate students in mechanical engineering, manufacturing engineering, and industrial engineering. Grahams suggestions were accepted by sealezes product development team. Greater role for other groups while still in the engineering phase such as manufacturing since almost 75% of the product cost is determined in the engineering phase, it gives a tool to attack. Grahams suggestions were accepted by sealezes product development team and incorporated into the final design.

Design and implementation of cellular manufacturing in a job shop environment by liana maria alvarez lopez b. Design for manufacture, which means the design for ease of manufacture of the parts that will form a product, and design for assembly, which means the design of the product for ease of assembly. Productionlogistic, engineering, assembly line control and quality management, it also ensured that the systems are well integrated and are usable globally. Nov 22, 2012 dfma design for manufacturing and assembly industrial product design aspects aesthetics shape, colour, texture material manufacturability, tolerance assembly convenience practical, technical, economical design for manufacture dfm and design for assembly dfa concurrent engineering lean manufacturing. The redesign of the ventilation unit with dfma aspects. Bim for dfma design for manufacturing and assembly. 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. Pdf dfm and dfa approach on designing pressure vessel. The method used to design a flexible, unique, controllable, and efficient cellular manufacturing system has become a topic that modern industrial operations are eager to learn and implement. Differences and similarities between design for manufacturing and design for assembly describe how product design has a primary influence basic criteria for part minimization quantitative analysis of a designs efficiency critique product designs for ease of assembly the importance of involving production engineers. The current design of laser jet printer had analyzed the design for manufacture and assembly to get the design efficiency and to reduce parts as well as the cost of production and manufacturing time.

The case study provides valuable information about how dfma could be applied to the construction industry. In this regard, validation evidence for two premises is sought through a case study at a small furniture production company. If a product contains fewer parts it will take less time to assemble, thereby reducing assembly costs. It a software comprised of various principles or methods when used properly will improve the ability of design to be easily manufactured and assembled thereby decreasing the costs. The kaizen technique has been proven as an effective tool for process improvement yung, 1996, process reengineering lyu, 1996, and even for. Crew size calculation for an assembly line doing one piece flow paced to takt time is.

Overview of design for manufacturing and assembly dfma. The paper first stresses the importance of taking careful account of manufacturing and assembly problems in the early stages of product design. A case study of lean, sustainable manufacturing 12 g. Pdf product design improvement by design for assembly dfa. Design for manufacturing and assembly dfma has great potential for minimizing late engineering changes ecs that impede highspeed product development and delay timetoprofit. Advances in human factors, ergonomics, and safety in manufacturing and service industries.

This case study requires the student to consider the problems and issues involved in the design of a final assembly plant in the automotive industry. Case study design to assembly contract manufacturing solution. The practice of applying dfma is to identify, quantify and eliminate waste or inefficiency in a product design. This case study shows how the effect of implementation of the design for manufacture and assembly dfma in product development process. Fujitsu provided design, implementation and maintenance. Design for assembly dfa and conceptual dfa criteria are used in the generation of costeffective assembly sequences for complex products. Review of design for manufacturing and assembly aspects to designing modern micro. After the cellular manufacturing system was introduced, a kaizen team was formed to design a. There are a variety of keapproaches, such as knowledgebased engineering, casebased reasoning and programming, which have been used in research to develop design for manufacturing methods and applications.

Kim 10 tma projection lens light source modulation stop tma. Crew size sum of manual cycle time takt time if manual cycle time 1,293 seconds and a takt time 345 sec crew size 1,293 personseconds 345 seconds crew size 3. The importance of involving production engineers in dfma. Dfma cutting billions in manufacturing costs since 1983. Another modification proposal was to eliminate the puncture and spot facing of the seat of speed sensor. The problem identified in this virtual situation is that the product is currently too expensive to produce. The design for manufacturing and assembly analysis and.

Part of their product line consisted of heavy insulated glass doors and side panel window inserts. Product design for manufacture and assembly sciencedirect. A methodology is proposed that helps to improve the productivity of any production process. Product design improvement by design for assembly dfa method. However, our understanding of dfma and its implementation in industry is still incomplete. Grahams expertise provided a few design for manufacturability changes specifically changing its draft that did not affect the products functionality, but made it easier to mold later in production.

This study is a part of design systems area, with formal approaches to models of design processes and knowledge. Two case studies with respect to dfma usage and its advantages are presented in the current study. Concurrent design design for manufacturing, assembly and x. The method of design for manufacturing and assembly dfma can be used to redesign a product. Such was the case a few years ago when the opportunity arose to develop a. In addition, if the parts are provided with features which make it easier to grasp, move, orient and insert them, this will also reduce. Pdf product development in an automotive component using. Dfma is the combination between design for manufacturing dfm and design for assembly dfa. Chapter 1 product design and development in the industrial. Design for assembly techniques in reverse engineering and redesign douglas d. In the case of an assembly line, due to the complexity, stochastic nature and interconnectedness between machines and other components within the manufacturing systems, predicting the likely performance of the systems without tools such as computerbased simulation is difficult baines and kay 2002.

Wood department of mechanical engineering the university of texas etc 5. The book has a profound interdisciplinary character and is addressed to researchers, engineers, phd students, graduate and undergraduate students, teachers, and other readers. It stresses the importance of design for ease of manufacturing and assembling of components that will form the final product. Design for manufacturing and assembly methodology applied. This system can be divided into three major sections. Mars international client of natick, ma was established by the venture engineering firm, manifold products, also based. Dfma design for manufacturing and assembly industrial product design aspects aesthetics shape, colour, texture material manufacturability, tolerance assembly convenience practical, technical, economical design. By simplifying the design of a product it is possible to manufacture and assemble it more efficiently, in the minimum time and at a lower cost. Engineering design methods are stated and their advantages in design activity are revealed. Powered conveyor assembly line line balancing equipment selection automotive industry abstract.

Design for manufacturing and assembly delivers product. Design for manufacturing and assembly dfma siemens. An ebanking case study pdf, 238 kb data from the national bank of spain show how the customers voice can be designed into its ebanking system. Introduction to design for cost effective assembly and manufacturing. Training is a valuable investment, but companies dont expect immediate profits from the training sessions themselves. Then, using a case study, the philosophy of the design for manufacture and assembly dfma methodology and its application are explained.

Photo courtesy of gemcor systems as indicated in chapter 8, assembly of aircraft as well as other shell structures like ships and automobiles is accomplished in part by means of fixtures. Dfma advantages quantitative method to assess design communication tool with other engineering disciplines and other departments sales, etc. Dfma stands for design for manufacture and assembly. At whirlpool sweden in norrkoping, though, this was exactly the case as they trained crossfunctional teams of inplant personnel to perform design for assembly dfa analysis. Some manufacturing solutions require a great deal of development and production of component parts as well as assembly. Pdf product design improvement by design for assembly. Engineering concepts in industrial product design with a case. Design for manufacture and assembly oriented design approach to. Design for manufacturing case study protocam additive. Design for manufacturing and assembly key performance.

Design for manufacturing and assembly dfma 7 with this modification a cost reduction occurs in 0. Engineering concepts in industrial product design with a. Design for manufacturing and assembly dfma method is introduced by geoffrey boothroyd since 1960s on automatic handling. Dfma and service design section b group e 19 nov 12 2. Boothroyd and dewhurst products sources of information used. Design for manufacturing dfm a case study of repetitive. A primary strategy in dfm involves minimizing the number of parts in a product. Design for manufacture and assembly dfma is a design approach that focuses on ease of manufacture and efficiency of assembly. Design for assembly dfa is a process by which products are designed with ease of assembly in mind. A case study is showed to testify the advantages and benefits achieved when the proposed tool is used. Design for manufacture and assembly dfma designing. This was true in this case study, where mars international acted as a manufacturing partner providing both plastic and metal components. Redesign on vehicle front support structure using dfma abstract. Design for manufacture and assembly software helps the company to reduce assembly costs and times.

Pdf this case study shows how the effect of implementation of the design for manufacture and assembly dfma in product development. The methodology consists of selecting a product or product family. Components are reduced to their simplest form to optimize. Dfma design for manufacture and assembly in the stage of product design, with the full. Case study design to assembly contract manufacturing. Implementation of cellular manufacturing in process industry a case study dr. Pressure vessel was selected as the example in this case study.

Using boothroyd dewhurst design for manufacturing and assembly software engineers score 40 percent total savings on slot machine part and assembly costs. Design for manufacture and assembly dfma designing buildings wiki share your construction industry knowledge. Implementation of cellular manufacturing in process. Afterwards, the detailed design is defined and physical prototypes are realized before to start the production phase. Pumps are then tested, painted, packed and delivered to a finished goods store. Problem definition the firm is located in south india and it is a leading manufacturer of electrical control panel assembly exclusively for wind turbines. Dfma is used as the basis for concurrent engineering studies to provide guidance to the design team in simplifying the product structure, to reduce manufacturing and assembly costs, and to quantify improvements. Purpose statement to provide an overview of design for manufacturing and assembly dfma techniques, which are used to minimize product cost through design and process improvements.

Design for manufacturing dfm refers to design activity that is based on minimizing the cost of production andor time to market for a product, while maintaining an appropriate level of quality. The dfma approach when applied in the building and construction arena, requires a change in the relationship between design and construction. Dfma is an abbreviation for design for manufacturing and assembly. Design for manufacturing and assembly dfma is an engineering methodology that focuses on reducing timetomarket and total production costs by prioritizing both the ease of manufacture for the products parts and the simplified assembly of those parts into the final product all during the early design phases of the product lifecycle. Design for manufacturing and assembly methodology applied to aircrafts design and manufacturing. Dfma stands for design for manufacturing and assembly. Case study the focus of this project is the virtual manufacture of meat tenderizers. Paper open access design for manufacture and assembly for. Applications of design for manufacturing and assembly. Agency files away inefficiency, saves taxpayers a bundle pdf, 228 kb. In this chapter, a case of study applying design for x dfx techniques and statements are analysed, with emphasis on design for assembly dfa. A kaizen based approach for cellular manufacturing system. Design for manufacturing and assembly delivers product improvements by emphasizing which of the following. A toolholder carousel of a cnc machine a toolholder carousel of a cnc machine tool for wood processing and machining has been analysed within this work as a.