Design For Manufacturing PDF

Design For Manufacturing
Fall2005- ENGR 3200U
Product Development Process

Planning
Planning
Concept
System-Level
System-Level
Concept
Development
Design
Design
Development
Detail
Detail
Design
Design
Testing
Testingand
and
Refinement
Refinement
Production
Production
Ramp-Up
Ramp-Up
How can we emphasize manufacturing issues

throughout the development process?
Case Study: Design of General Motors

3.8-Liter V6 Engine
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.
High production
volume:
A team was formed to
improve on of the
most expensive
subassemblies in the
engine: the air intake
manifold
Case Study: Design of General Motors

3.8-Liter V6 Engine
Original and the
redesigned
manifolds:
Molded
Thermoplastic
composite
instead of the cat
Aluminum
Determination of Product Cost
Design For Objective

Functions (DFX)
Design for Manufacturing (DFM), Assembly (DFA),
Quality (DFQ), and design for any other objective
functions (DFx)
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.
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.
Three Methods to Implement DFM

1. Organization: Cross-Functional Teams
2. Design Rules: Specialized by Firm
3. CAD Tools: Boothroyd-Dewhurst Software
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
10
Understanding Manufacturing Costs

Manufacturing Cost
Components
Standard
Raw
Material
Assembly
Custom
Labor
Processing
Tooling
Equipment
and Tooling
Overhead
Support
Indirect
Allocation
11
Total Manufacturing Cost
12
Design for Assembly Rules

Example set of DFA guidelines
from a computer manufacturer.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Minimize parts count.

Encourage modular assembly.
Stack assemblies.
Eliminate adjustments.
Eliminate cables.
Use self-fastening parts.
Use self-locating parts.
Eliminate reorientation.
Facilitate parts handling.
Specify standard parts.
13
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
14
To Compute Assembly Time
Handling Time
+ Insertion Time
Assembly Time
15
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.
16
DFA Index
DFA
N 3
index =
t
N= Theoretical minimum number of the parts. An estimation of

the results of parts integration
t= Actual time of the assembly
17
Videocassette DFM Exercise

2 billion worldwide annual volume
7 major producers of 1/2 cassette shells
JVC licenses the VHS standard
dimensions, interfaces, light path, etc
VHS cassette shells cost ~$0.25 each

What is a $0.01 cost reduction worth?
18
Computer-Based Approaches to
DFM
Computer Aided DFM helps simplify the effort and shortens
the time required to implement the DFM on a daily basis
There are many Computer Aided DFA tools available.
Not many Computer Aided DFM are represented
Example:
Boothroyd Dewhurst Incorporated (BDI), sells modules for
DFA, casting, and electronic manufacturing.
Ahmad Barari, H. A. ElMaraghy, Design for Machining
Software
19
Case Study: Computer Aided

Design for Machining
1- Definition of the NURBS Surface
20

Design for Machining (DFMc)
2- Design Tolerance Definition
t u = 0.06 mm
t l = 0.06 mm
Profile Tolerances
Rotation Tolerance about the X - axis = 0.0001 rad

Rotation Tolerance about the Y - axis = 0.0001 rad
Rotation Tolerance about the Z - axis = 0.0001 rad
Design Tolerances
Position Tolerance in the X - axis = 0.1 mm

Position Tolerance in the Y - axis = 0.1 mm
Position Tolerance in the Z - axis = 0.1 mm
21

3- Machine Tool Errors Modeling
PXYZWT
- (1 + (-xRz - Sxy) yRz - (xRy + Szx) yRy) zTx
- (-yRz - xRz - Sxy + (xRy + Szx) (yRx + Syz)) zTy
- (yRy + (-xRz - Sxy) (-yRx - Syz) + xRy + Szx) (zTz - GZ)
- yTx - (-xRz - Sxy) (yTy - GY) - (xRy + Szx) yTz - xTx + GX
- (xRz + Sxy + yRz + xRx yRy) zTx
- (-(xRz + Sxy) yRz + 1 - xRx (yRx + Syz)) zTy
- ((xRz + Sxy) yRy - yRx - Syz - xRx) (zTz - GZ)
=
- (xRz + Sxy) yTx - yTy + GY + xRx yTz - xTy
- (-xRy - Szx + xRx yRz - yRy) zTx
- (-(-xRy - Szx) yRz + xRx + yRx + Syz) zTy
- ((-xRy - Szx) yRy + xRx (-yRx - Syz) + 1) (zTz - GZ)
- (-xRy - Szx) yTx - xRx (yTy - GY) - yTz - xTz
22

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
23

5- Error Distribution before using DFMc tool
24

6- Error Distribution after using DFMc tool
25
Design for Quality (DFQ)

Principles
Quality excellence can best be achieved by preventing problems
rather than by detecting and correcting them after they occur
26
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 problem solving; teams, that have customers, suppliers,
quality, marketing, manufacturing, assembly, etc. functions
represented. Let them get involved with the design at an early stage.)
27
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 "mistakeproofing" 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 system which is developed basis
that errors can always be prevented.
28
Poka-Yoke Example
29

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Design For Manufacturing

Fall2005- ENGR 3200U

Product Development Process

How can we emphasize manufacturing issues

Fall2005- ENGR 3200U

Case Study: Design of General Motors

Fall2005- ENGR 3200U

Case Study: Design of General Motors

Fall2005- ENGR 3200U

Determination of Product Cost

Fall2005- ENGR 3200U

Design For Objective

Fall2005- ENGR 3200U