DFA ANALYSIS ON WATER PURIFIER

A project report submitted for J component of MEE 2008 – Product Design for
Manufacturing (E2+TE2)

Bachelor of Technology in Mechanical Engineering

By
Kaushik Dhivakar – 18BPI0030
Surya J- 18BPI0044
Navin Sivaa G – 18BPI0058
Nishanth M – 18BPI0068

SCHOOL OF MECHANICAL ENGINEERING

MAY,2021
TABLE OF CONTENTS

CHA TITLE PAGE

PTER NO.
NO.
EXECUTIVE SUMMARY / ABSTRACT 3
LIST OF TABLES 4
LIST OF FIGURES 5
1 INTRODUCTION AND LITERATURE REVIEW

1.1 DESIGN FOR ASSEMBLY 6

1.2 ABOUT THE PRODUCT 8
1.3 OBJECTIVES OF THE WORK 9

2 METHODOLOGY AND EXPERIMENTAL WORK

2.1 METHODOLOGY 10
2.2 CRITERIA FOR ELIMINATION 11
2.3 MODEL CONCEPT AND DESIGN 12
3 RESULTS AND DISCUSSION 15

4 CONCLUSION
4.1 CONCLUSION 18
4.2 FUTURE SCOPE OF WORK 19
5 REFERENCES 20
ABSTRACT

We are performing DFA analysis using Boothroyd Dewhurst's method to

minimize number of parts, total operation and assembly time and operations
costs. The theoretical minimum number of parts are assigned by asking 3 simple
questions

 During the operation of the product, does this part move bodily with
respect to all other parts already assembled?
 For fundamental reasons, does the part have to be of a different material
from all the other parts already assembled?
 Does the part have to be separate from all other parts already assembled
because otherwise assembly or disassembly of other separate parts could
not be carried out?

The results of the applications of design for assembly techniques to two typical
designs are presented. Consideration is given to the total product cost and it is
found that major cost reductions can be achieved even when assembly costs are
relatively small. It is also found that assembly automation becomes more
difficult to justify as a product design is gradually improved.
LIST OF TABLES

TABLE NUMBER TITLE PAGE NUMBER

1 Round 1 DFA Analysis 16

2 Round 2 DFA Analysis 17
3 DFA results 18
LIST OF IMAGES

TABLE NUMBER TITLE PAGE NUMBER

1 Assembled water purifier 12

2 Assembled water 12
purifier(origin view)
3 Top lid 12
4 Top cover 12
5 Micro fiber mesh 12
6 Top chamber 12
7 Activated carbon trap 13
8 Trap mesh 13
9 Batching chamber 13
10 Germ Kill indicator 13
11 Germ kill processor 13
12 Cylindrical carbon trap 13
13 Thread fastening 14
14 Tap 14
15 Transperant chamber 14
16 Collecting chamber 14
17 Pedestal 14
INTRODUCTION AND LITERATURE REVIEW

Design for Assembly

The Boothroyd Dewhurst DFA (Design for Assembly) tool is a powerful

instrument that fosters innovative and collaborative product design. Those who
are new to the process may struggle with how to begin. The intent of this paper
is to provide a stepby-step guide for commencing a DFA analysis and lay the
foundation for achieving the benefits of the DFMA methodology. Concurrent
engineering and design-formanufacturing efforts in the electronics and other
industries are steadily superseding the costly practice of manufacturing a system
to a quite unfamiliar design. In the new climate, designers and manufacturing
engineers work together, and the teams are asking for software that meshes
design with manufacturability. Design-for-manufacturing software programs
give the designers of printedcircuit boards (PCBs), well ahead of tine, a better
idea of how densely populated with parts a finished board will be and what
manufacturing problems it will present. Concurrent engineering teams are also
asking for automated tools that enable them to predict not only board density,
height, and Boothroyd and Knight-Design for assembly Called from Boothroyd
DewhurstS PCB/DFA operations library, this screen highlights a cleaning
operation. The labor rate for cleaning a given board has been entered, along
with the Droduct lifetime volume and number of cleaning setups, into the
library, from which cleaning costs are calculated. other physical properties but
also what the finished board will cost to manufacture. For more than a decade,
Texas Instruments Inc., Dallas, has worked on a partsbased system of analysis
that predicts the cost of manufacturing a circuit board. Meanwhile, Boothroyd
Dewhurst Inc., Wakefield, RI, was gaining experience from its commercial
Design for Manufacturing and Assembly (DFMA) software, and six years ago
joined forces with TI to apply that experience to circuit boards. The DFMA
software was developed in 1980 for analyzing the manufacturability of
mechanical designs. During the conceptual stage of a product’s development,
the software makes a comprehensive analysis of a design, its materials
requirements, manufacturability, and estimated cost, allowing an engineer to
build an information base for evaluating the manufacturability of a design step
by step. Using results obtained by the software, Ford Motor Co. showed that 80
percent of all product costs are fixed at the design stage.
MANUFACTURABILITY INDICES. Together, TI and Boothroyd Dewhurst
have evolved a software program that not only predicts a board’s cost but also
provides indices of its manufacturability. Called PCB Design for Assembly
(PCB/DFA), the software is intended to reduce designcycle time and
manufacturing cost. Well before placement and routing, the software quickly
generates “on paper” alternative board designs that would be economical to
manufacture.

An essential ingredient of DFA, known as the DFA Index, provides a way to

measure assembly efficiency. It is a ratio of the theoretically ideal assembly
time over the actual assembly time. The range is from 0 to 100, with a higher
number representing a more efficient design. The DFA Index is based on
decades of performing time studies and collecting data by Boothroyd Dewhurst,
and it can be used to compare alternate design concepts that have been created
to meet the same functional requirements. The DFA Index can also be used to
make data driven decisions, instead of relying on instinct, gut-feel, or intuition.
The formula for calculating the DFA Index is shown below. Ema represents the
value for the DFA Index. The Numerator in the equation is defined by the
theoretically ideal assembly time, where Nmin is the Theoretical Minimum
Number of Parts multiplied by ta, the Ideal Assembly Time for a given part,
which is equivalent to 2.93 seconds. The Denominator is defined by the
Estimated Assembly Time, tma, which includes penalties for handling and
insertion difficulties, along with time penalties for operations and parts that
don’t meet the Minimum Part Criteria. The DFA Index can be used as a
quantitative metric to track the progress of product development. It also
encourages Product Simplification by facilitating creativity.
About the product

Fig 18 Pureit water purifier (Taken from official website)

Pureit water purifier is designed to give approximately 1500L^ of purified water

and Germkill Kit™ -2 gives approximately 2250L^ of purified water
respectively depending on input water pressure, TDS and water temperature.
Objectives for work

This review provides the details about how DFA can be used for re-engineering
the water purifier used in the Indian market. The following works are conducted
for designing a better product:

• Analysis of existing product assembly with the help of

DFA
• Identification of improvement possibilities.
• Design alterations to improve design efficiency and
 Validation through DFA
 Reducing assembly time and operation time
 Improving design effiecieny thorugh Boothroyd Dewhurst’s (theoretical
minimum number of component reduction) method
 Reducing overall assembly cost
METHODOLOGY AND EXPERIMENTAL WORK
Methodology

1. First step is identify the product.

2. The product is then disassembled and individual parts are modelled in
CAM software.
3. DFM costing analysis is carried out on individual parts followed by
4. DFA analysis to identify the parts for elimination.
5. Various redesign concepts are applied
6. Those parts are then remodeled in CAM followed by DFM
7. analysis.
8. Finally, models of original & redesigned products are compared

Considerations/Assumptions

 The first part is essential (base part)

 Non-essential parts: – Fasteners – Spacers, washers, O-rings –
Connectors, leads
 Do not include liquids as parts (e.g.. glue, gasket sealant, lube)

Part Identification
 List parts in the order of assembly
 Assign/record part number

Count Parts & Interfaces

 List number of parts (Np)
 List number of interfaces (Ni)
Criteria for part elimination

According to minimum part criteria, for any part to exist, there can only be only
one of the following reasons:

• The part forms the base of the product

• The part needs to be of a different material
• The part needs to move relative to other parts
• The part is separately designing for ease of assembly.

The part which does not follow anyone of these, is suitable for elimination.

Eliminated Parts are NEVER

 Designed
 Detailed
 Prototyped
 Produced
 Scrapped
 Tested
 Re-engineered
 Purchased
 Progressed
 Received
 Inspected
 Rejected
 Stocked
 Outdated
 Written-off
 Unreliable
 Recycled
 late from the supplier
Model concept and design

Fig 1 Assembled water purifier Fig 2 Assembled water purifier

Fig 3 Top Lid Fig 4 Top cover
(origin view)
L=61 cm, W= 29 cm, D=26 cm L=16cm , T=3cm
D= 10cm, T= 3cm

Fig 5 Microfiber Mesh Fig 6 Top Chamber

D= 12cm, H= 15cm H= 30cm, W= 29cm

Fig 7 Activated Carbon Trap Fig 8 Trap mesh

D= 9cm, H = 5cm D = 10cm, H = 6cm

Fig 9 Batching Chamber Fig 10 Germ kill indicator

H = 15 cm , W = 29cm H= 10cm , T = 2cm

Fig 11 Germ kill processor Fig 12 Cylindrical Carbon trap

H= 8cm, D= 5cm H = 12cm , D= 10cm

 Fig 13 Thread fastening Fig 14 Tap

D= 4cm , H = 5cm D= 2cm , H = 7cm

Fig 15 Transperant chamber Fig 16 Collecting chamber

H = 30cm, W =29cm H = 30 cm , W = 29 cm

Fig 17 Pedestal

W = 29cm , T = 5cm
Results and Discussion
Redesigning oppurtunites

The following oppurtunities were during this study

• Elimination of Pedestal
• Replacement of germ-kill processer from the batching chamber to top
chamber.
• Combining cleansing collection chamber and transparent chamber
together.
• Fixing up activated carbon trap and trap mesh together.

Elimination of pedestal

• Since the pedestal that is given for the purifier to stand is not so useful.
The purifier can even stand alone without the pedestal, so this part can
be eliminated which helps in cost reduction.
• In Order to keep the purifier on the floor, we have to increase the height
of the cleansing collection chamber, so than a glass can fit under the tap
when the purifier is place on the floor.
Replacement of germ kill processor kit from its position.

• In the original product, the Germ kill kit is attached to batching chamber
which does not have any other function expect holding the Germ kill kit.
• So, this Germ kill kit can be attached directly to top chamber which also
has activated carbon trap inside it.
• This replacement involves the elimination of a part which results in cost
reduction.
Combining cleansing collection chamber and transparent chamber together.

• In the original product, the cleansing collection chamber and transparent

chamber are two different parts which just only increases the assembly
time.
• So, both of them can be fixed together and the for cylindrical carbon
trap to open when it has to be replaced, it can just be opened from the
transparent chamber inside.
 Final part after combining –

Fixing up activated carbon trap and trap mesh together

• In the original model, the Activated Carbon Trap inside the top chamber
has given a mesh over it which is not attached to it.
• Since, the Carbon Trap has no replacement facility even in the case of
broken. So there isn’t any use for the Trap and Mesh separated to each
other.
• Therefore, the mesh is attached permanently to the trap which saves
theassembly time.
Final part after combining-
Boothroyd Dewhurst’s DFA Round 1 Index

number
of times two-
the digit two- opera operati theora
S manual manual
operati man digit tion on tical
. handlin insertio
Part name on is ual manual time,s cost, minim
N g time n time
carried hand insertio econd cents um
O per part per part
out ling n code s 0.4*(7) parts
consecu code
tively
1 PEDESTAL 1 30 1.95 00 1.5 30 0.6 0
cleansing
2 collection 1 91 3 00 1.5 91 0.6 1
chamber
transparent
3 1 91 3 00 1.5 91 0.6 0
chamber
4 tap 1 35 2.73 39 8 74 3.2 1
thread
5 1 21 2.1 39 8 60 3.2 1
fastening
cylindrical
6 1 83 5.6 00 1.5 83 0.6 1
carbon trap
germ kill
7 1 30 1.95 39 8 69 3.2 1
processor
germ kill
8 1 30 1.95 30 2 60 0.8 0
indicator
batching
9 1 91 3 00 1.5 91 0.6 1
chamber
1 Activated
1 10 1.5 30 2 40 0.8 1
0 carbon trap
1
trap mesh 1 10 1.5 30 2 40 0.8 0
1
1
top chamber 1 91 3 00 1.5 91 0.6 1
2
1 microfibre
1 10 1.5 30 2 40 0.8 1
3 mesh
1
top cover 1 30 1.95 00 1.5 30 0.6 1
4
1
top lid 1 10 1.5 00 1.5 10 0.6 1
5
80.23 32.092 11

Table 1 round 1 DFA Analysis

Boothroyd Dewhurst’s DFA Round 2 Index
number
of times two-
operat
the digit two- operat theorat
S manual manual ion
operati man digit ion ical
. handlin insertio cost,
part name on is ual manual time,s minim
N g time n time cents
carried hand insertio econd um
O per part per part 0.4*(7
out ling n code s parts
)
consecu code
tively

Transperant
Cleansing
1 1 91 3 00 1.5 91 0.6 1
collection
chamber
2 tap 1 35 2.73 39 8 74 3.2 1
thread
3 1 21 2.1 39 8 60 3.2 1
fastening
cylindrical
4 1 83 5.6 00 1.5 83 0.6 1
carbon trap
5 germ kill kit 1 30 1.95 39 8 69 3.2 1
batching
6 1 91 3 00 1.5 91 0.6 1
chamber
Activated
7 carbon mesh 1 10 1.5 30 2 40 0.8 1
trap
8 top chamber 1 91 3 00 1.5 91 0.6 1
microfibre
9 1 10 1.5 30 2 40 0.8 1
mesh
1
top cover 1 30 1.95 00 1.5 30 0.6 1
0
1
top lid 1 10 1.5 00 1.5 10 0.6 1
1
64.83 25.93 11

Table 2 ,round 2 DFA Analysis

Conclusion

Conclusion

WATER FILTER ROUND 1 ROUND 2 PERCENTAGE CHANGE

DFMA INDEX 0.41 0.5 22%

PART COUNT 15 11 26.67%
ASSEMBELY TIME 80.23 sec 64.83 sec 18.98%
ASSEMBELY COST 32.092 25.93 21.885%

Table 3 , DFA results

The intent of a DFA analysis is to evaluate the efficiency of an assembly,

unleash team creativity to improve the assembly, and compare alternate design
approaches. The first few attempts at conducting the DFA analysis can be
overwhelming for novice users of the Boothroyd Dewhurst DFA software tool.
Skill in using the tool can be increased through regular practice and use,
coupled with review of the items outlined in this paper. Another way to gain
competence with DFA analysis is to experiment with different responses for the
parts, to see if the results reflect what is expected, and what actually happens.
Ultimately, DFA analysis leads to simplified product designs and helps teams
achieve the impossible.

 This review illustrates the various DFA considerations in the design of a

existing consumer product used in the Indian market.
 Overall cost savings of 7 was achieved with the elimination of 1 part for
the redesigned Water Filter.
 64.83 seconds of assembly time is achieved by redisgning few points.
 Although, the cost reduction is equivalent to 21.885% of total product
cost, these savings in cost per product can boost the profitability of the
company.
 Part count is reduced to 11 parts from 15 after elemination
Future scope of work

We have used DFA analysis to reduce the part time, assembly time,
assembly cost. our research opens up different opportunities to research and
improve more in water purifier. the research also creates motivation to
improve design efficiency further more. This research model and analysis
can also be implemented in RO-Reverse osomosis system that we use in our
homes. along with DFA analysis we can implement DMA i.e. design for
manufacturing. future research includes material selection and incorporating
manufacturing can improve the design efficiency and all other parameters.
References

1. Assembly Automation and Product Design

G. Boothroyd, Marcell Dekker, Inc. 1992
2. Product Design for Manufacture and Assembly
G. Boothroyd and P. Dewhurst, Boothroyd Dewhurst, Inc. 1989
Marcell Dekker, Inc. 1994
3. Boothroyd, G., & Knight, W. (1993). Design for assembly. IEEE
Spectrum, 30(9), 53–55.
4. James Moultrie, Anja M. Maier. (2014) A simplified approach to design
for assembly. Journal of Engineering Design 25:1-3, pages 44-63.