INTRODUCTION FOR DESIGN FOR MANUFACTURE ASSEMBLY (DFMA)

Design for manufacturability (also known as design for manufacturing & assembly (DFM/DFA) is the application of process, methodology and art of creating cost effective product designs. The design stage is important and ultimately influential in the end-product cost, quality, and time to market. Overall product lifecycle characteristics are committed at design stage. The product design is not just based on good design or engineering factors but it should consider the through-put or ease of manufacturing as well.

COURSE OBJECTIVES

1. Understand and perform Boothroyd/Dewhurst assembly efficiency analysis
2. Designing for mistake proofing (poka yoke)
3. Minimize part count
4. Modular design
5. Top down assembly
6. Reduction of fasteners
7. Specify standard parts
8. Facilitate parts handling
9. Minimize reorientation at assembly
10. Minimize cables
11. Minimize final adjustments after assembly

COURSE CONTENT

1 .Boothroyd/Dewhurt DFA efficiency analysis

1. Boothroyd/Dewhurst assembly efficiency analysis method & tables
2. Part weight
3. Part shape & symmetry
4. Part thickness
5. Chamfer design
6. Combination
7. Assembly layout
8. Workshop 1: Performing an assembly efficiency analysis

2.Part count reduction method

1. 3 principles of part count reduction
2. Workshop 2: Part count reduction activity

3.Modular design method

1. Modular design guidelines
2. Workshop 3: Modular design activity

4.Top down assembly

1. Top down assembly guidelines
2. Workstation ergonomics
3. Workshop 4: Top down assembly design change

5. Reduction of fasteners & parts standardization

1. Standardization guidelines
2. Snap fit guidelines
3. Workshop 5: Reduce the number of fasteners with design change

6.Facilitate parts handling & orientation

1. Using Table 1 & Table 2 from Geoffrey Boothroyd
2. Spaghetti diagram of before & after
3. Workshop 6: Design change to improve assembly index

7.Design for automatic & robot assembly

1. Design for high speed feeding & assembly
2. Feeding difficulties
3. Rules for high speed assembly & automation
4. Workshop 7: Automatic assembly design improvement

8.Design for Manufacturing

1. General requirement for material & process selection
2. Selection of manufacturing process

a.Sheet metal stamping

b.Plastic injection molding

iii. Workshop 8: Material & process selection

9.Designing for mistake proofing (poka yoke)

1. What is mistake proofing?
2. Design guidelines for mistake proofing
3. Workshop 9: Design change for mistake proof- ing

10.Action plan

1. Capturing Issues with Build Reports
2. Closing the Loop with a Final Product Review
3. DFM/A Performance Measurement & Metrics