nit 5

Desiqnfot X.

LDeign Fk manufachuein4 assembl aag

applied
is a pazt ol deiiqn ptocesT can he
phase atprodud deign
henchma|king anaysis Simplityinq
Ohich are no
Cmhodied desiani
-T facilkates fo making piele parh eis
ptodu Cen diom tao MatetiolI invave
Lapplicationo pat foming modeli, anl
fozmwa oe Compley finite element pccer'
Simiobon
- DEMA iS Vety esSeotia fo)
becaite ha theee maio advantaqa i
it zecuce parl Count here by ik zc duce la
4Anay f eiqn is eay
Qssermble i! Canbe produced in less tim 4t
vey cheapez
DEMA Connist d Varioww ptiniples i we
thee einiplea peopcely ilhLzmgtove the
ig to Casilymanufchuedsaie
t
Maoz Gectni at OEMA Syitem
Raw mateia
3
Machin
Assemblie
4 Peocey
 PagY No.
Dato: II

1. RacaoMateri al
Eoundahon at good design is choice at
oateial, hosenmate riad ut be have Cozie
chemical t4 mechonical pzopezhes as pezdesigs
Citera : aae should aauo Conide cost cohi le
GUechaq mateziat
Machine 4 ProceS
Main Obiecive isis toeduee thel.ime
equied
oz pAoduchon coith raaintained quali y ot parh
choseo proceS Ghowd be hest aneby conAidekiy
au prameterl ike
toolioqfiniGhiaqsolan4
tg
3: Assemblies
bociaiAn

Dexign CouotWe
Shoulg be simple e shodd teduce doke
Showd Combinemewliple pazh
pa
parh ghodd he
Tcnqlinqio pacis ghold he 2voided ai 4hey
Aakeconideraion ime to unlongle Apply
poke yte 4 miStake

LAdyonlaqesa parh g total pals caunt

zeducesasSeghlyapin
3 e d u c e s t o t a l e a d ime
b,T teducespackagiag Hm
improves praduchviy telfuieney
 AsScmbl (DEA
Desiqn [o Assembl
LOepiian
T iS Aideline Set ak intuchon1 iRe
a foedign
delul
hurtheL as sdten dexign gucenequia
f earc handling
easeetattaChmenl
fnau gdein

Guideline)i
Number o part oun}i asSemhly sho.
be
minimized by comnhining differeol Ancks
in to Single funchon.
OiCtexeot
Diffetent art Should be combine in t Singe
Suh aisemhy
petectthe
Lainserhon.
pari regardinq is ozienlaksn d
Pari shbLld be standatdized t zeduce the ave
Maimum no od
parts shoutd be Symmetia
Remaye the
Ayoic nestngdcnqlinq
af path
pah
paahng path shodd he desiqned foe sct
inseton
fasteneI, Ghodd be }emoed
Locahon f faleoer Should be
Ohstuion
Neoparth in he assemby houtd betocke
be
abave
ea
acceii at
ehanntls ghad be fatening
 Page No.
iOato,

System Guidelinei:
LA dhis Sytcm Scl
ataay ofqutdelinel. delecd
thai pat! functian Cencach
part in Suoh 4tvey
be perioAMed bby instead
na a pats shold neghboting
pazl Sccendl
bezeduced through aremhly
aodulatt
Handling uidelines:
The pott ohich are Qoing to aasemble mut
be handled Handling incluae akn the pazt
Srom the locahan convey'hese path
Jacathoo to dhe poin!Osbere we acetomn
to aasemhly fo in Sexhion 4 Oient the parh
assembig
Tasetthion Gudelines .
oe shoald wse
chamcted pah ffae Sack ot oas
in sezhon aiqnment characteishc shauld be
peoided an
On aiSemhly So thal ne parh cas
be Pasily oientedithod poeaaltemen1.

Joining Guidelipes:
Toseted parh in the Qisembly musl be
Lotached oith t he help a joiaing ptoces, hs
lan be done oith the help ot Sone fasteoc23.
LadbesiYepeid) There shodd he oini

II is vety impolont to eai2e he fact chol

is Ahal ee e shold Combine
ossenbly
ulbalpatb intoainale att oneingle
 o| Robuslocss -
Desiqn
be! set otn
Rabulkdeianis to selcch the
Confiqrahanparamnetets cohih Satisie) d
oinimumd.
peztomance 5 peihca honso1th
manufa ttute,mateialO ie
due tu
This concept al tobusl deign qne
engg qualiky idtascl custunaes
about

Peoduct
Mateial ooiquwaion ertrnance
Manut:Varato Clohichau as Yaziation
tzansfe fun)

Pesign tonigurar
`lecho

Eq: facho thal Can cha nqe Deliveed ferfoimante

Consiuthion odRobul! Design Modelo
ial SBep dettcbion ot
ptoblemnohat detcYminatan
is the teasan hehind
ot vath
how to measure ils effect varaion
halcan be done

measteroen a
To pepare tabualPertuknonde ariable
produt
ptoduct desian Shottol ca
iablpertomance citczig ,Thete shelo be c
 Page No.
IData:
pectomane
heze
shoud Natiablel
he
oz
tobiil desiqn
o vazng
LL Shiuldperzmance
be
Contoos phical operoh
phyical
of operahve ccikm
melicS mealuze affailre bothdesiqn4noiic
per tomance melzic fthis votish.
pertoa
detcc lailute nodelwe Shacld
mode (EMEA) Éailure mode cE Eech
Anal)
Then we Shold
meaute
hink aboJ wha coe
Cwidh Lunit 1epzeient this faiure
oe should also Conidee
al pzaduc the stna peifo

(auses Of atiain NojSe Vatiabtes

Manufachiog
bonA
noisea Thele are
mgnufaching vatia
peoduct Votable)Ckeotion of ib4cne
Doise due to
Totcr0al noise: SpOanufoctuting
These peodu arda hoxOs air Cais
Ldue ta deqrodabion o| depreciakon Eg LOROl
Exterral noiSe:Thisats dueto extena fach lia
ikeuSer intrat hion, vatiation in temp. 4 otbs
eOyitonmental factpS.

Lbesiqn okoz Safel

is an impoztont issue n ptoduct desiqn
satet
e takel Satety'asguatad qtanledunsafc
peoducth on hh NiecscOstty ntimi at produ
4 peodu kpubahion.
iabili
here atethàee patametez todesign foz Sakeht
Pzepate the pzoduct fo Safe e shodd desiq
he pto duotioSuchlaoaythat al haLo di
Shosld beotto)
2. TI iEis not possible to pzepate the eeduct
 Page No,

9afe thes desiqn ShoLldinchude

LComplekely
Qroteive deviceslike
to
eliminate bazatd
kemONe

to hen e
cwaLoin like
apptoptiat
aud Sounoli. labels,flashing
iahh
Fail- sae Desiqn=
IL is the desiqn which ensueS thadolailoee
oil) Deitbet affect he pzodutt no Chang
b a Stote in ohich
hich o injuy oe' damaqe
oill QCCut

Types oÆ fail-scfe Design 2

4. fail Passive deiqn
2 fal Acive Deliqn
a fail apakianal"Deliqn.
auidelinci for Desiqn fo Salety
Recanise and detect poteok hazard t acoldiny
deiqn the ptoducB So that oi)) polaffecd
Ls funchon
Exomine the
hozords
hazards vestoke
ye ype etully to teveal 'any
P2oduc lootedin theinital. deaign u
oesi4ndhe pendue S dhat is easie t
RRaise
aVoid t
Hhe ettoa
ptoduce Completely
efiendly ptepare
 Page No.

Uato: / /

Lail- sclc Appteach.

This apptoah is to detec cocak gpok in dhe
Companenl 0e ill po wide Some
ttangemeol o nmootolcthat lweaknU
The LoeGk linkisjs teplaceo teplae
io houichodin enqy elecltial Guppl
baard The ob<echve af dhis de iqn s hal
Campanena in the
Sheld have equal fif thatthe
operatt an its f l zange ti the e l at ih
aetu ifetime sange
Coute o nzeliahi ky
1 Deliqr mistakes Cwcko Calculakan, paal hoateis
Selechan)
2 manufacturinq delech ÇPoce Q0zking e
4ttainina)
maintenAnce énptopet pefalmance)
h Exceecling deliqn imih ipmih ct tempzalk
Speccd)
5.Envizonmentalfactol CRasn humidity 4ice)
Desiqn Ptachce ta Tmptove Reliabil
ke shoutd hmain kainmatqin cf slley dueinq
Hhe de od pzodul fo qvid the failute
DezahngThe analagi ing fachu scley
Lia dexoinq cot omenhReiabhiliy s such
eaipme)is
Conditions are
3Outabi liy
ionsedifmaimu
derated beloscdhiz namepat
opealiag
 Page No.
Date:

Ease o! Tnspechion.

Cost Riabiliy
Cost fotal cost

Cost attez deliyey

Jeost of design
maoufa ctuee

Reliabilih
The cust od eliabiliky Cenaei ftom pzta Calty
associated oith deiqninq4peoducing mde
teliahle coropanenls,eukng a teliabiliz
droinin 4 maikainingaeliabiliy
Oganizotion
Deign Fo Envitonment
adeiga deam
Dornaqinq ot envitormentis intluenced
inthe Cor deign phales
TO dals cutomezs ate asriOq the pzdduch with
Jess
ervizonmeo tal impad. As he paplahen
o he
thus Gacilty is 4tying to minimize
Now
cadtomet aredemanding en
fziendiy ptoduc teal0n hehindiE 3
theze is qeneraion ot sevezol pes at po
 Page No.

wDate:

DEE GLw'delne CEnitonm¢ndad bËechvca

4 Pzatection o Biosphere
Companiel coill yto minimlze dhe teiea2e
pollutants cohich wil pud the Patthhinn dengei
2. OpLimum se a
ue tai matezial al optimm
leve ohère they ceCan beSu Aained.

B. Reducbon and
anddisposal ad oele
ninimnize
whereevetposslble Companies L-CannotaoitheJas te
he
they woill odopl
they
|4.
4 Oplimum uie ol enerqy
Companie i coil1 Qefo
fo etòánmeA inveiimca
nenerqy Conse Yahon Theyiuaill pzeer envitor

Sate energ
menit Sailsk

5. Recuchan in Risk
tisk to
HealHhtiak to emplayeel } 4the Commur oi
be rminimizeed by the Companio

qat Safe ptoduttoand Servce.

CompaniekTaai adept the palicy at the matkebi
the pzoduhs ohic ha co) mioimizeepvitonmenta
impalls 4 areSafelh Conau oe to ie
7.
Damag e Campensahion L
effe4
envizonmpn). Responiibilih to clean
 Page No,

Compensae the batmhl etfecl ill be bold

by the Compan.
8. Disc loSute
Ioctdepts obich tesw in bam to eDVtonm
CEatc Safety O bealth
Create
haza
musl be Ceplained oL disclo Ged hy compan
Athe Cormmuniy
09. Eoveaomental Dieecto
A
SenioezeCub'vemembet Room the ompan
aill be looking in to the matte ot envi|onm
affaisAtleastOAE mmhet feoo the coMm
board coilbenominated toceptele! inte)
theeOvitoomenal issue.
Lo.Anoua Audi

DE GLMdelines -
A) Baxic DLE Gutdelines ko} matcial celechon.
BoicDE quidlelioe foe peoduc ShuchuLe
gideinea foz labelling Anish
D) Baiic DEE gdeline) R fast ening

LDerign fo Reeyciog
izst re quiremeot foa tecycling a material in
peoclucd is that here oat be demand
for the matetiolgo 0e ghold use Commonl
tecycledateial Such almetalh4 plaies
Éach ptoduck Componentshould be ta kta
kecielahilik
tacdan tecyelabilih
2 Ratinq should b and aepakpcomp
giyen foech
baed n
2eyclabilily sepielabi hy
zati ng arelooet han ?
 Page No.
Date: / /
The
individual totinge Con dhen tte be Combi n
ealh Value basisin
3ubalsembly 4 foi the peoducd as hole.
oesiqn fot Remanulachucing
Desiqn fo Renaa nufactuzing S cobere
disossembled can becasily cleanbd 4inapka
-RemarDufachuing is ana end ot the life Sttatg
cobere Hhepeoducd is taken ta the Ceotzal
acili pdisassernbled Here interes is noB
Lin the but tha
pats Soteoleaned oto some cxteod
4 theninipeced
Therete 3
Steps aed inemanulcchsn
Ghepi Visual nspechor TH is Simply visuat
jnsper hon l disposibm TE he pradluck is
in bed ghape iis cejechod TLis Simply ge,n
visual'udgneo
slep2 Disasserably at the peoducl
disarceably peoud in toSuh se hal
LCan be patentiallyecyeledo emed. i
SepocudeLabozhence AisCoslly
Cteision ic made te Simpltky thi proceli.
daign Cleaning and inspeckon: paih tha a
to be temanutache oubetetuDe toa
Qualiby asgted
Deo Condition 4heil
 Page No.
i Date:

LDexign fox Piec Part Peoducon

LDeaign
DEA IS On One asp'ech at casi ng fhe
The erde othe aiperd is o Make each pau menufachs
eay t pzoduoeTI s Vey dihu
Foamulak guneal deiqal quidelhnag T
teay Simple4eaxy toan
make
guwdelinei oit
he prceASe aed o
Sheet métal DEM quidelineg
o plac ipatt tO£Ó quideing helta
S to Conit ptoduchon pnqineezin th PrOLe
Ldesiqn d thepartale
0e have 4uide ine aeaiqn anayis tol
many poceises in tha shee)
have auide lines onminimum bend adii
ocdal patl
ftahue Seperchan
Seperahon Cast parh heveeçan
odaioos f eatuei ocakon topovide nMada
ad patha cuzinq pmolad
machininq Opaionihave aidelineon di
QOvide qidelineG cfotaevcy
hacec neo prcduchon ptoces
upde teknedpdceri js
developnspt aenhonl4
Cast az DesiqnGuidelinel
1. Avoid ghazp Cane
2Pzovide odeofA ngle t help
3 Maintcin
LuhibM temoval a mold
Non unfnz1 Stchor hickn
hich oill hine Casel ho Spb
peodute
delech Deign
 Page No.
Date:

to_produce hol Gpob.

5_ Avaid
abtupl chengel
pal ct
in secki an dhicknesi
a the Cashaq cohich

7 daugn
Manufactwing Cost Anasis
aatsis=
Selling Peice

Manufachees DiSAzibuian Retail

COSt

Piece Path Assembly ovechea d

OEM Cestomi
Labo
Patt Park Toeling

SekupPeacosina
MateeialTooling 3Sekup
Eg Pzaducion Cast Analysis Becakdaan
Manufachuring cosk Anaysis 2
manutactutiog c0s beakdoo ConiisL di
1. Piece part Cost -The caslad bath patlamade 4bough
Casts n costalotasemblingttpotth jnhpuducl
Assembl
9. Oveheod tatehis coYeNs hc cishit uppocin
dizest ptoducha tpazh asemhlyhis include
 Page No
Dale:

the itemu
the
Cast al ptoducin

Cost modeling wecil Cansiodez

approach tha
The baic
dilkeren manutochuinq ptoce
modelling ct dtive ts a ptaces
divezs CoS
Considez Cos! pEoceS e
Ohich decides the Cost o the
in hzee categozie
Consider pact Co stk
pcoduchon ot
ost toling Cosi 4
1.. Material cosh
These are th Cosb t the taw mateials fotthe

par geaezaliy ezfpeessed in ptice pe pound

Mateial Cost pet unit: Pat (wAx Sctapx mat
2.
Tooling cost
These ae the ixed cosl to buy the
he equiam
CoOvert he materia in toEnishedat
02 Component
The Cosh include the Cost to deAiqn 4 fabticate
the tooling,
Tocling Cesl pez unil Equpnent tost pazis pu
equigns
3 Setup Cos
These are the Cosh hh se themochind up
bcgia. peoducion

Peocexing thelah
Cos!

keep th cqupmen! foaintenenccost to

ocen9 colkpez unitnning
 Page No.
VDate:

simila y
Aiemly cos pez unil lab) ratcpe hx pee
Jacal Peqional a Global unil

Local Reqiona) Tssue.

rmoe f
teve). eni|
heeanmeoAalptobienmsOccut) at tegional
problemi ae acid zaD i
4 aate pollion Acid taio fois)ce to polluhn
produC in one teqion CanaLie acid
tainin
notheetegionAi pallukon
Lalso 2eqiona prohlem oate 4 Smeq iare
in the tive glound atebay pollution occu
t caional problem Tl is Cased by
peahci des
Shteet Oatrz noH in
theSutbwbengouthen a s
1 Aci Rain
TLis ategianapolubon problem tohich is cauaed
bË exce1sive fossi fuel a) emission foa tegiaoal
areoThee fuel combusko produch produch qel
qe) teleased
into Hhe ait and cauude tain i9 gtaunding
eDvironment do havelowee acidic PH teel.
Can Cause hazotdto
- 10hich gianal planb
LaeteSulfcredA ar as prode
Ldesi r is Conc£LNLd develapmani ot pzodue cuhick
less enerqLH coil hep
Aiz Poluhiona
T i S a sionilat prhlemaaLsed b÷ exceisive foil
tuel erbi ssions foz aZegionalareal Q20ne,caLbn
enoridu nitogen cmpounda supha dioxjede oa ae
emenptoblen tu]comhshnprodush hick
 Date: / /

zeleas edio to dhe ai.

Developoneol al producl cohich coill
cnergzil) help ekminatt thiS problem
Oatea palluhan
Watc alluion is anthez Souece
Sazce thOLgh hirt
eithe eotez n ahica
Cuntaminanhcon
theogh catc foce Shcem AheeDvitonm
landEILS.
PestideA 4 hehicides Le problemahc Compoud
whase amount intzoduceda teqional area Malk
be controled othe chfmical Compauady that
cie seal in he ptoduch mut be realizecl
conttulled

These Cestaio poluhonptoblem which

offect oqlobal scale Theie ptoblemii ioclude
ClimatChanqe, Qzan depieb'og
bisdivesihy toai
CiOate
Due to
chog
incceare in q2eeo boAe gaSes tu
laxqe dzomethicclimate chanqe
change in eat th's cimak

perceotcqeaf calbon dioxid

gubsinicond oin th atmusp

Deplebon at fhe 02e0e layeea

layee
Oz0n terpeyeottaiolek tadiah
oSurN
eppeGtm
 Paga No..
Data: /

Minimi2in
ais Biodivesib Lwss
issue alo qlobals
Iin cludes lossot Impath
babikat
sfoe iezentplanh
specieA due to ezponhiun at
Saiety Cao ause echo ytero4 erinchs
Io o2de to eiminate this prable o
Such ptoduch thod se tess

Baic Lic Cycle AsscAsmenk

AssesSoeoh - Besc methocl

This peocess
ptOcesS help iatn
to 2eali2eimpott ot a p2od
fzomManufa Chuze
proceis theaugs uwe thcouqh
ineludes folling glea
dipa

Siepi aloha dehoiion

Ihis Sleps include ConsideAahon ct envitonmental
Laisesientin ducd detign n wde to establ1L
Ctear okechve.
Shep2 Envizonmental Tmpactaventht
Ahe qoal then Gcapeoproduc
Aate deiainq shi muowe gequen
tea Shoutd be dened a ife icycle Gtaqe
ackvike) Cach Called

TmpadaiseIme nfAttez shudyinq

Slepg ichald be i mpa
Syteea Hhere stem Weate havin too baic melhods

carey Methool,
 Page No.
Date: |

TntceptcBation ACkck
Aftce ompleing the ales
Can be dtscusseo
cscuseo sz in fepzeed
apportunihdt to Change the
imravehe envitonncotal Objechye
O QVala ble alteNabye
Comparc amongi.
Method
Lile ycle AsscAShcnt
LCA iS complete numeial
Conticer
anasis
áctuaJ
q
impac Heeee
mpad Conidein the atial pro ducken
opeain dispssa Stenm aed Here cDe
not Conideiaa the aseraqe Vaue
Tozeqional
this
impacd
hat methodn inVeDtn2+ s
Ocoueitomal
a
during thh
peactis dutig
Amissio

Summarized ins
emission zeleasedal a
materioJ used fal coQltaqe qenezatcd
fox each
materiaJ Steps,
teqitementare deidefozthe
actua ptoduc!al 0el Qsemission teye
peoduced The Vadues ot each SLage af h
produd's Jite Cycle Qre then Gummed
toith appzoptiate unih
+LCA_tesulh is aCcUate
accLEAHe Complelecomplhf
nayss is telerved fo ahence thce
reducioninthe
-mfutuee LCA
oal foz produ
Cost analysishe scodard s

develapmeot.
 Page No.
Data: /

Topub
Qut puts
Raw Materíal Acquisiion
Mateial L a t e r emmision
Ptocessing & anufacturing
atm emisSior
Distibuion Tanspotahon lobal warminq
Enerq Zon epletiG Smog

welmaintenance Re-ule Solidwate

Recycle thozardous iqiel

Daste manogem ent Rodioachuit

usable eoduct
iq: franme too2k fo developinq a likycle
Analylis. Likgle
Dusiqn failueemode EEfeck Analysis -
I is echnique ot predictisg the failee Ceitezia
o aajot fuoctional part ad prouct and Stud
peosuct of
Iompac od those (titeias d failute on pzoduct
This kechoique effect
efmEA e
failure mode
Anatyis
classihes falur es
CSíect
T j5 adopded coidet
cotsidecig exteo

al advanced peoducd qaly

odtheiz

-planning
failute modde. erect
Desin
b Process Lailte
£a m0de Anayia
 age No

DENNEA PtoccS

io
Aceas of Analysig
DEMEA Robs

Iode of failte

ECfect of failete

Causes Of Falure

Extent Seveei

Guide a Gequenial and ogical elesignproca:

DEtect andteduce tisk io
deign
-Peepate a dacument fo desiqo and dexelapnae
Peoper
A ushAcahon ol desiqo actiiy
platfotm fer Conkoawpodud OimpoNe
1. Risk Pioribumhe
(ReN)
9.
Detection
o ptoduct
of signik Cant and Cital
ce
Chatacte'

Benefts al EmEA
TL avoids
detects failwe
itical betoce they heppe
factsabbd pacessand
dexans
necdeEidenhies here Ahe focu)t con120
 Page No,
i Data;/

enaptavement and Coninous

GtteduceA
ptevent
lAnal
feldncostand
failuee Sctap
tisk
Dieqiam
letaithipsmKA
Requitcm
tomez

hot

o0soti0g mos bvi91

CHun

hosal ot
Sasstach

prtso99

rodoibri 9a