Concurrent Engineering

Rule base method :- Design for Assembly

Lecture Session 05

Eng. K.C Wickramasinghe

BSc(Hons), AMIESL
Dept. of Mechanical & Manufacturing
Engineering,

Faculty of Engineering,
University of Ruhuna.

01

Introduction
Definition: A process for improving product design for easy and

low-cost assembly, focusing on functionality and on assembly

concurrently.
Aim: To simplify the product so that the cost of assembly is
reduced.
Initially developed by Geoffrey Boothroyd in mid 1970s.

02

Assembly Methods

Manual Assembly

Automatic Assembly

Robotic Assembly

-Workers manually
assemble the product or
components of a product

-Special purpose assembly

machines

-Programmable
assembly machines

-Assemble one specific

product

-Use robotic assembly

systems

-Hand tools are used

-Flexible
-Problem when
production increases

-Controlled by PLC or
computer

-Labor costs

03

Assembly Methods
Relative costs of different assembly methods by type and production
volume.

04

Evaluation methods for DFA

Boothroyd-dewhurst method

Based on two principles

1. The application of criteria to each part to determine if
it should be separate from all other parts.
2. Estimation of the handling and assembly costs for each
part using the appropriate assembly process.
Lucas method (early 1980s by Lucas Corp, UK)

05

Boothroyd-dewhurst method
Relies on an existing design which is iteratively evaluated and

improved.
Steps:
1.

Select an assembly method for each part

2.

Analyze the parts for the given assembly methods

3.

Refine the design in response to shortcomings identified by

the analysis
4.

Loop to step 2 until the analysis yields a sufficient design

06

Worksheet for analysis

Sample Boothroyd-Dewhurst DFA worksheet

Part
ID#

i*

# of
Consecutive
identical
operations

2-digit
handling
code

Manual
handling
time/
part

2-digit
insertion
code

Manual
insertion
time/
part

Operati
on time
(bd+f)

Operation
cost

Essential
part?

Tm=

Cm=

Nm=

Totals go here ->

Nam
e
of
asse
mbly

Boothroyd-dewhurst method
Parts are evaluated as to whether it is really necessary (in the
assembly) by asking three questions:
Does the part move relative to another part?
Are the material properties of the part necessary?
Does the part need to be a separate entity for the sake of
assembly?

All parts are then evaluated to obtain the minimum number of

theoretically needed parts, denoted by Nm.

Boothroyd-dewhurst method

Design efficiency = (Assembly time for a part x Nm) / Tm

Lucas method
Boothroyd-Dewhurst method is based on timing each of the
handling and insertion motions
Lucas method is based on a "point scale" which gives a relative
measure of assembly difficulty

Lucas method is based on three separate and sequential analyses

Functional analysis
Feeding analysis
Fitting analysis

Functional Analysis
The components of the product are reviewed only for their function
and divided into two groups A and B
Group A - those that are essential to the product's function
Group B - those that are not essential to the product's function
Design efficiency = A / (A+B)x100%
Typically, a design efficiency of 60% is targeted for initial designs.

Feeding/Handling Analysis
Both the part handling and insertion times are examined

(similar to Boothroyd-Dewhurst analysis)

Component is awarded a score on its ease of handling

Feeding Ratio

(Total feeding/handing index)

Number of essential components

Ideal feeding ratio 2.5

Lucas DFA method - Manual Handling Analysis

Handling Index = A+B+C+D

B. Handling difficulties
All that apply

A. Size & Weight of Part

One of the following
Very small - requires tools

Convenient - hands only

Large and/or heavy
requires more than 1 hand

Large and/or heavy

requires hoist or 2 people

1.5

1
1.5

Delicate

0.4

Flexible

0.6

Sticky

0.5

Tangible

0.8

Severely nest

0.7

Sharp/Abrasive

0.3

Untouchable

0.5

Gripping problem / slippery

0.2

3
No handling difficulties

C. Orientation of Part
One of the following:

Symmetrical, no orientation req'd

End to end, easy to see

End to end, not visible

0.1

D. Rotational Orientation of Part

One of the following
Rotational Symmetry

Rotational Orientation, easy to see

0.2

Rotational Orientation, hard to see

0.4

0.5

Fitting Analysis
Need to know the proposed assembly sequence
Relative difficulty in assembling the complete product is
determined.
Whether the component needs to holding in a fixture
The assembly direction
Alignment problems

Restricted vision
Required insertion force
Fitting ratio =Total fitting index/No. of essential components

Lucas DFA method - Manual Fitting Analysis

Fitting Index = A+B+C+D+E+F

B. Process Direction
One of the following

A. Part Placing and

Fastening
One of the following

Straight line from above

Self-holding orientation

1.0

Straight line not from above

0.1

Requires holding
Plus 1 of the following

2.0

Not a straight line

1.6

Self-securing (i.e. snaps)

1.3

Screwing

4.0

Riveting

4.0

Bending

4.0

D. Access and/or
Vision
One of the following
Direct
Restricted

C. Insertion
One of the following
Single

0
1.5

E. Alignment
One of the following

Multiple insertions

0.7

Easy to align

Simultaneous multiple insertions

1.2

Difficult to align

0
0.7

F. Insertion Force
One of the following
No resistance to insertion
Resistance to insertion

0
0.6

Manufacturing Analysis
Find the cost of manufacturing each component

Not a true cost but guide the designer by giving a relative

measure of manufacturing cost