Pokok Bahasan:

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Material Properties & Type
Material Selection
Design for Manufacturability
Tolerance
Design for Assembly
Design for Environment
Economic & Manufacturing Cost

Design for
Manufacturing and Assembly

Assembly
Manufacture
Shape
forming

Shape
change

Finish

Assembly

Handle

Handle

Handle

Handle

Primary
manufacturing

Secondary
manufacturing

Tertiary
manufacturing

Join

Shape forming

Machining

Coating,
treatment

Fasten

Inspect

Inspect

Inspect

Inspect

Insert

Assembly Processes
Joining
Welding, brazing, soldering
Riveting

Inserting
Pin, keys, locators, etc (transitional or
interference fitting)

Fastening
Bolts and nuts
Pressing

Taxonomy of Assembly
Operations
Electronic assembly
Wiring
27%
SMT
15%
Soldering
12%
Through hole insertion
7%
Cabling
5%
Cleaning
4%
Miscellaneous
30%

Mechanical assembly
Fastening by screw
or bolt
38%
Riveting
26%
Pressing
6%
Miscellaneous
30%

Economic Significance
Other Production
47%

Assembly
operations 53%

Feeding, handling, supervision,

adjustment, inspection 50%

Mating , joining
50%

Materials and other production

80%
Setup
12%

Total time in
production

Assembly
20%

Total unit
production cost

Intermediate
Assembly

Final
Assembly

Support including quality

management, design, facility, etc.

24%

24%

20%

Types of Assembly
Manual assembly
Assembly with
automation support
Special purpose
assembly machines
Programmable/flexib
le assembly
machines

Important to
achieve line
balancing

Objectives of DFMA
Design rationalization and parts reduction
Modular design

Parts and system interchangability and

standardization
Process plan rationalization
Adapting optimized manufacturing process flow
Integrated design, manufacturing and measurement

Enhanced assembly procedure and

measurement
RATIONALIZATION OF PRODUCT DESIGN!

Benefits of DFMA
Reducing the number of
parts
Optimising manufacturing
processes
Simplifying parts handling
Improving product
assembly

Average parts count

reduction - 46%
Average assembly cost
reduction - 47%
Product cost reduction - 15%
Reduction in parts related
costs
Assembly tooling cost
reduced
Product introduction lead
time reduced
Product reliability improved

http://www.teamset.com/design-for-assembly-2.html
http://www.teamset.com/frame2.html

Assembly Relationship
Assembly relationship can be
represented by entity-relationship
diagram.
Entity is a component
Relationship is the functional
relationship and include
information on the assembly. In
assembly analysis, this is called the
liaison diagram.

Entity Relationship Diagram

Entity
System
level

Relationship

Entity

Database

Knowledge base
Component
level

Case 1 - Sub-assembly level

E1 - power plug
E2 cable cord
R1 - power transmission,
E1
red wire to the live pin
blue wire to the neutral pin
green wire to the ground pin
cable cord fixed by cord grip to base

Database

R1

E2

Example - Plug
1
4

Component
ID

Component
name

Functional
attributes

PLUG-1

cover

housing

base, cover screw

PLUG-2

ground pin

safety

base, fuse clip

PLUG-3

neutral pin

power
transmission, 13A

base

PLUG-4

live pin

power
transmission, 13A

base, fuse

PLUG-5

fuse clip

fuse location

ground pin, fuse

PLUG-6

cord grip

cable location

base, cord grip screw

PLUG-7

fuse

safety, 13A

fuse clip, live pin

PLUG-8

base

housing

cover, cover screw,

ground pin, neutral
pin, live pin, cord grip
screw, cover screw

PLUG-9 x 2

cord grip screws

cable griping

base, cord grip

PLUG-10

cover screw

housing assembly

base, cover

9
10

Note: The wire gripping screws

are assumed to be part of the pin
sub-assembly and are not
included in the parts list

Mating
component

Entity Relationship
Diagram
P1 (cover)

P10 (cover screw)

P6 (cord grip)

3
6

9
10

P9 (cord
grip screws)

P8 (base)

I
I

P4 (live
pin)

P2 (ground pin)

P3 (neutral pin)

J
P5 (fuse clip)

P7 (fuse)

Assembly Sequence
Analysis
Assembly drawing and part list, parts
drawing
Generate E-R diagram
Assign precedence and follower
relationship
Generate precedence order graph
(assembly sequence graph)
Checking and optimization

Liaison Diagram
Liaison diagram similar to ER
diagram
Build relationship between entities
and check all possibilities for
precedence
Consider the feasible ones

Liaison Sequence Diagram

Each row contains one or more state elements containing
empty or filled-in cells.
Each state corresponds to a feasible subassembly or as many
as two feasible subassemblies.
Each cell in a state corresponds to a liaison (relationship).
Empty cells indicate liaisons that have not been done, while
filled-in cells indicate completed liaisons.
Each line between states is a transition, during which one or
more liaisons are done.
A path from the top state (no liaisons done) to the bottom
state (all liaisons done) is a feasible liaison sequence. This
diagram expresses two feasible sequences.

Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development, D.E. Whitney
Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development, D.E. Whitney

Example Automobile
Alternator
Sequence 1
Attractive single direction, no reorientation
Hard to access the front housing,
difficult to tighten screws for the
bearing retainer

Sequence 2
Place rear housing in a fixture and
adds parts to it
Front housing built as sub-assembly,
Fixture to grasp the retainer while
screws are inserted
Requires two re-orientations, front
housing and whole assembly
Undesirable re-orientating an
unfastening subassembly
Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development, D.E. Whitney

Example Automobile
Alternator

Sequence 3

Attractive single direction, no reorientation

Differ from Sequence 1 with a front
housing built on separate fixture
Additional fixture additional cost

Sequence 4 used by manufacturer

Front housing built on separate fixture
Manual inspection on the front housing
sub-assembly
single direction, no re-orientation
Not the best solution

Conclusion:
Very hard to get an optimized
assembly sequence
Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development, D.E. Whitney

DFA

Basic Rules for DFA

Design parts with end-toend symmetry or
rotational symmetry about
axis of insertion.
If parts are not symmetric,
they should be obviously
asymmetric
Avoid design that cause
jamming or entanglement
during storage
Avoid designing parts that
have poor handling too
small, too large, sharp,
splinter, delicate, slippery,
flexible, etc.
Chapter 3, Product design of Manufacture and Assembly , Boothroyd
and Dewhurst

Rules for Insertion &

Fastening

Design for smooth

insertion: Clearance
fit with no jamming;
air relief passage,
chamfer, selfalignment

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Rules for Insertion &

Fastening

Standardization
and
interchangeability:
common parts,
processes, and
methods across
product lines
Use Pyramid
assembly best to
assemble from
above

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Rules for Insertion &

Fastening

Avoid holding down

parts during
placement

Design for
consistent part
location on release

Choose low-cost
mechanical design
Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Examples
handling
self-alignment
asymmetric
insertion - chamfer
non-tangling
easy orientation and
self-alignment
reduction of parts

Examples

Assembly Efficiency
Boothroyd and Dewhurst developed a
systematic method for DFA.
a classification and coding system for
manual handling, insertion and
fastening processes
Assembly efficiency:
The number of parts in a product
Ease of handling, insertion, and fastening of
the parts

Example Power Saw

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Example Controller
Assembly

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Controller Assembly
Worksheet Analysis

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Design Changes and

Savings

Controller Assembly
Redesign

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Additional Guidelines
Avoid connections

Design for
unrestricted access

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Additional Guidelines
Avoid adjustments

Use kinematic
design principles

Chapter 3, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Design for Assembly

Automation

Basic Considerations
Design for ease of automatic feeding,
orienting, insertion, and assembly
operation
Rate (cost per unit time) for all operations
including the machine, the system, and
the down time should be known
Cost of all the equipment
Number of operators and technical staf
Designed assembly rate

Example
Feeding equipment rate: Rf=CfEo/(TPbSn)
Rf is the feeding equipment rate in cents/second
Cf is the feeder cost converted to cents
Eo is the equipment overhead ratio
T is the number of seconds per shift per month
Pb is equipment payback in months
Sn is the number of shifts

Vibratory bowl feeder:

Cf =$30,000 = 3,000,000 cents (including installation &
maintenance); Eo = 2 (100% overhead); T = 864,000
seconds/month (8 hour shift for 30 working days); P b = 18
months; Sn =2 (2 shifts)
Rf = 3,000,000 x 2 / 864,000 x 18 x 2 = 0.193 cents/second
Max. feeding rate = 10 parts/min. = 1/6 parts second
The feeding cost / part = 6 x 0.193 cents = 1.1574 cents.

Time Estimation

Ergonomics study to
support time estimation
Automation handling:

Geometric classification:
Rotational: disc,
short cylinder, long
cylinder
Non-rotational: flat,
long, cubic
Symmetry
Asymmetric projections,
steps or chamfers

Feeding

Thin edge shingling &

overlapping
Flexible, tangling, sticky,
light-weight

Insertion

Alignment and positioning

Insertion path (vertical)

Chapter 5, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Example

Chapter 5, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Chapter 5, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Design Parts for

Feeding and Orienting

Avoid design
parts that
will tangle,
nest or
shingle
Make parts
symmetrical
For
asymmetric
parts, avoid
slight
asymmetry

Chapter 5, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Additional Rules

Additional Rules
Reduce levels of assembly and part
counts
Capitalize on material properties
Design parts with a base structure to
support assembly operation
Support a vertical insertion assembly
operation
Good ergonomics design

Reduce levels of assembly

and part counts

Adopt the strategy of

modular design and
interchangeability in
design
Reduce flexible
parts, harness and
cables etc, via
design integration
Use self-fastening or
snap-fit features
Reduce the levels of
assembly

Example

Me-Mo Modular Cellphone Design

Snap-fit

Chapter 5, Product design of Manufacture and Assembly , Boothroyd and Dewhurst

Capitalize on Material
Properties
Built-in spring
http://www.engineer.gvsu.edu/vac/

Part integration pressed,

molded, or extruded parts,
- sheet metal, plastics
http://plastics.tuthill.com/Products/Insert
%20Molding/Insert%20molding.asp

Stable Base Structure

Minimize assembly
set-up proper
orientation
Good ergonomics
design for assembly
operation good
visibility and
reachability
Adopting standardized
fixtures and tools

Example

Vertical Assembly Insertion

Aligning parts for assembly operation
Minimize orientation error
Self-locating design

References
Boothroyd Dewhurst http://www.dfma.com/
http://www.npd-solutions.com/dfmguidelines.html