Fall2005- ENGR 3200U 1

Design For Manufacturing

Fall2005- ENGR 3200U 2
Planning
Planning
Product Development Process
Concept
Development
Concept
Development
System-Level
Design
System-Level
Design
Detail
Design
Detail
Design
Testing and
Refinement
Testing and
Refinement
Production
Ramp-Up
Production
Ramp-Up
How can we emphasize manufacturing issues
throughout the development process?
Fall2005- ENGR 3200U 3
Case Study: Design of General Motors
3.8-Liter V6 Engine
High production
volume:
A team was formed to
improve on of the
most expensive
subassemblies in the
engine: the air intake
manifold
GM powertrain division manufacture about 3500 3.8 Liter V6 engine
every day. A strong interest in reducing the cost of engine while
simultaneously enhancing its quality.
Fall2005- ENGR 3200U 4
Case Study: Design of General Motors
3.8-Liter V6 Engine
Original and the
redesigned
manifolds:
Molded
Thermoplastic
composite
instead of the cat
Aluminum
Fall2005- ENGR 3200U 5
Determination of Product Cost
Fall2005- ENGR 3200U 6
Design For Objective
Functions (DFX)
Design for Manufacturing (DFM), Assembly (DFA),
Quality (DFQ), and design for any other objective
functions (DFx)
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Design for Manufacturing
Design For Manufacturing (DFM), represents a new awareness of the
importance of design as the first manufacturing step.
It recognizes that:
Company can not meet quality AND cost objectives with
isolated design and manufacturing.
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Definition
Design for manufacturing (DFM) is a development
practice emphasizing manufacturing issues
throughout the product development process.
Successful DFM results in lower production cost
without sacrificing product quality.
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Three Methods to Implement DFM
1. Organization: Cross-Functional Teams
2. Design Rules: Specialized by Firm
3. CAD Tools: Boothroyd-Dewhurst Software
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Five Steps of DFM
A cost based five steps process
for DFM is suggested:
1- Estimate the manufacturing
costs
2- Reduce the costs of
components
3- Reduce the costs of assembly
4- Reduce the cost of supporting
production
5- Consider the impact of DFM
decisions on the other factors
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Understanding Manufacturing Costs
Manufacturing Cost
Components
Assembly
Overhead
Standard
Custom Labor
Equipment
and Tooling
Support
Indirect
Allocation
Raw
Material
Processing
Tooling
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Total Manufacturing Cost
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Design for Assembly Rules
Example set of DFA guidelines
from a computer manufacturer.
1. Minimize parts count.
2. Encourage modular assembly.
3. Stack assemblies.
4. Eliminate adjustments.
5. Eliminate cables.
6. Use self-fastening parts.
7. Use self-locating parts.
8. Eliminate reorientation.
9. Facilitate parts handling.
10. Specify standard parts.
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Design for Assembly
Key ideas of DFA:
Minimize parts count
Maximize the ease of handling parts
Maximize the ease of inserting parts
Benefits of DFA
Lower labor costs
Other indirect benefits
Popular software developed by
Boothroyd and Dewhurst.
http://www.dfma.com
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To Compute Assembly Time
Handling Time
+ Insertion Time
Assembly Time
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Method for Part Integration
Ask of each part in a candidate design:
1.Does the part need to move relative to the rest of the
device?
2.Does it need to be of a different material because of
fundamental physical properties?
3.Does it need to be separated from the rest of the
device to allow for assembly, access, or repair?
If not, combine the part with another part in the device.
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DFA Index
N=Theoretical minimumnumber of the parts. An estimation of
the results of parts integration
t=Actual time of the assembly
t
3 N
index DFA

=
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Videocassette DFM Exercise
2 billion worldwide annual volume
7 major producers of 1/2 cassette shells
J VC licenses the VHS standard
dimensions, interfaces, light path, etc
VHS cassette shells cost ~$0.25 each
What is a $0.01 cost reduction worth?
Fall2005- ENGR 3200U 19
Computer-Based Approaches to
DFM
Computer Aided DFMhelps simplify the effort and shortens
the time required to implement the DFMon a daily basis
There are many Computer Aided DFA tools available.
Not many Computer Aided DFMare represented
Example:
Boothroyd Dewhurst Incorporated (BDI), sells modules for
DFA, casting, and electronic manufacturing.
Ahmad Barari, H. A. ElMaraghy, Design for Machining
Software
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Case Study: Computer Aided
Design for Machining
1- Definition of the NURBS Surface
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Case Study: Computer Aided
Design for Machining (DFMc)
2- Design Tolerance Definition
mm 0.1 axis - Z the in Tolerance Position
mm 0.1 axis - Y the in Tolerance Position
mm 0.1 axis - X the in Tolerance Position
rad 0.0001 axis - Z the about Tolerance Rotation
rad 0.0001 axis - Y the about Tolerance Rotation
rad 0.0001 axis - X the about Tolerance Rotation
mm 06 . 0 t
mm 06 . 0 t
l
u
=
=
=
=
=
=
=
=
Design Tolerances
Profile Tolerances
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3- Machine Tool Errors Modeling

=
1
xTz - yTz - GY) - (yTy xRx - yTx Szx) - (-xRy -
GZ) - (zTz 1) + Syz) - (-yRx xRx + yRy Szx) - ((-xRy -
zTy Syz) + yRx + xRx + yRz Szx) - (-(-xRy -
zTx yRy) - yRz xRx + Szx - (-xRy -
xTy - yTz xRx + GY + yTy - yTx Sxy) + (xRz -
GZ) - (zTz xRx) - Syz - yRx - yRy Sxy) + ((xRz -
zTy Syz)) + (yRx xRx - 1 + yRz Sxy) + (-(xRz -
zTx yRy) xRx + yRz + Sxy + (xRz -
GX + xTx - yTz Szx) + (xRy - GY) - (yTy Sxy) - (-xRz - yTx -
GZ) - (zTz Szx) + xRy + Syz) - (-yRx Sxy) - (-xRz + (yRy -
zTy Syz)) + (yRx Szx) + (xRy + Sxy - xRz - (-yRz -
zTx yRy) Szx) + (xRy - yRz Sxy) - (-xRz + (1 -
P
XYZWT
Case Study: Computer Aided
Design for Machining (DFMc)
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4- Machine
Calibration Data
Error Parameter Description Error Value
xTx Positioning Error in X-axis Translation 0.0250 mm
xTy Y Straightness in X-axis Translation 0.0450 mm
xTz Z Straightness in X-axis Translation 0.0230 mm
xRx Roll of X-axis Translation 0.000019 rad
xRy Pitch of X-axis Translation 0.000145 rad
xRz Yaw of X-axis Translation 0.000024 rad
yTx Positioning Error in Y-axis Translation 0.0300 mm
yTy Y Straightness in Y-axis Translation 0.0760 mm
yTz Z Straightness in Y-axis Translation 0.0050 mm
yRx Yaw of Y-axis Translation 0.000010 rad
yRy Roll of Y-axis Translation 0.000048 rad
yRz Pitch of Y-axis Translation 0.000072 rad
zTx Positioning Error in Z-axis Translation 0.0040 mm
zTy Y Straightness in Z-axis Translation 0.0050 mm
zTz Z Straightness in Z-axis Translation 0.0025 mm
zRx Pitch of Z-axis Translation ----
zRy Yaw of Z-axis Translation ----
zRz Roll of Z-axis Translation ----
Sxy Mutual Squareness of X and Y axes 0.000029 rad
Syz Mutual Squareness of Y and Z axes 0.000034 rad
Szx Mutual Squareness of Z and X axes 0.000019 rad
Case Study: Computer Aided
Design for Machining (DFMc)
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5- Error Distribution before using DFMc tool
Case Study: Computer Aided
Design for Machining (DFMc)
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6- Error Distribution after using DFMc tool
Case Study: Computer Aided
Design for Machining (DFMc)
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Design for Quality (DFQ)
Principles
Quality excellence can best be achieved by preventing problems
rather than by detecting and correcting themafter they occur
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DFQ (Design For Quality):
Eliminate the need for, and
dependence upon inspection
Eliminate the need for, and dependence upon inspection to achieve
quality by building quality into the product in the first place. Design for
quality, manufacturability, assembly, maintenance, etc. Design quality
into the product, process and/or service. (In terms of CE, think of
team-oriented problemsolving; teams, that have customers, suppliers,
quality, marketing, manufacturing, assembly, etc. functions
represented. Let themget involved with the design at an early stage.)
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Design for Manufacturing and
Improving Product Quality by
Preventing Defects (Poka-Yoke)
Poka-Yoke is a technique for avoiding simple human error and aiming
for zero defects at all levels of work. (Poka-Yoke means "mistake-
proofing" or "fail-safing".)
The fundamental concept is that any kind of mistake is made by
people and that people make fewer mistakes if they are supported by
a design/manufacturing/assembly systemwhich is developed basis
that errors can always be prevented.
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Poka-Yoke Example