MODULE -4

DESIGN FOR X
Design for X [DFX]
There are many other factors to be
considered in the design to make it
competitive in the market.

These needs are grouped under

Design for X

Here X stand for specific design

objectives for which a product is
designed.
X- represent variables any specific
 Design for X
Design for quality
Design for Manufacturing/Construction
Design for Assembly/Fitting
Design for Safety and Reliability
Design for Maintenance & Serviceability
Design for Logistics
Design for Disassembly and Recycling
 Design for X-
Design for Quality-DFQ

Designing a product by considering various

aspects of achieving quality
Quality means compliance of something with
the requirement
Criteria for good quality
Superior functionality
Best fit
Least rejection
Durability
Serviceability
Justifiable cost
 Design for X-
Design for Manufacturing/Construction [DFM]

Main objective is to make the cost of realization

of the product low.
Reduction in parts and their costs.
Use of standard parts/subcontracted items.
Design using Group Technology-is an approach in which
similar parts are identified and grouped together in order to take
advantage of the similarities in design and production.
Change in materials if possible
Design for error proofing-poka yoke- identification of
all potential human error and elimination by proper design process
Use wider tolerances wherever possible.
Provide simple patterns and fastening.
 Design for X-
Design for Assembly (DFA)

Assembly is often the costly part in

manufacture.
Assembly automation to reduce the time and
cost is not easy.
Manual assembly is very costly.
However by designing the product suitably
many assembly operations can be automated.
Vertical assembly is good for ease of
assembly.*
Reduction in screws and quick location of parts
make the assembly quick.
 Design for X-
Design for Assembly (DFA)

Minimize number of parts

Provide self locating features on
parts
Design parts with self-clamping
features
Avoid reorientation of parts during
assembly
Use Top down approach for
assemblies
Use standard parts in the design
 Design for X-
Design for Safety and Reliability[DFS and DFR]

Product safety is to be ensured in design.

This covers the materials used, design
aspects on safety in operation, fool
proofing, warning systems etc.
Identify all the foreseeable hazards
reasonbly right form conception to disposal

What safety systems are needed in an

automobile and in an airplane?
Driver assistance
DADS:'DADS: Driver Alertness Detection System.System to prevent crashes
caused by fatigue
Automatic Brakingsystems to prevent or reduce the severity of collision.
Infrared night visionsystems to increase seeing distance beyond headlamp range
Reverse backup sensors, which alert drivers to difficult-to-see objects in their path
when reversing
Backup camera
Adaptive cruise controlwhich maintains a safe distance from the vehicle in front
Lane departure warning systemsto alert the driver of an unintended departure
from the intended lane of travel
Tire pressure monitoringsystems orDeflation Detection Systems
Traction control systemswhich restore traction if driven wheels begin to spin
Electronic Stability Control, which intervenes to avert an impending loss of control
Anti-lock braking systems
Emergency brake assistsystems
Assured Clear Distance Aheadmeasurement and speed governance systems
Precrash system
Automated parkingsystem
Obstacle detection sensor systems
Design for Safety..What is a safe
product or system?

No injury to user, (products liability)

No injury to consumer /society
No injury to production worker (e.g.
OSHA)
No damage to personal property
No damage to real property
(environment)
 Hazards
hazard a source of danger which has the
potential to injure people or damage property
or the environment

Hazards include
1. Entrapment pinch, crush
2. Contact heat, sharp edges, electric
3. Impact hammer, robot arm
4. Ejection grinder sparks, saw dust
5. Entanglement hair, clothing
6. Noise & Vibration hearing loss, HAVS
Conditional Circumstancesthings
change over time!

1) hazard is inherent during normal use

2) hazard originates from a component
failure
3) hazard caused by user misuse
4) hazard exists during normal maintenance
5) hazard created by improper maintenance
6) hazard stems from lack of maintenance
 Design for X-
Design for Reliability [DFR]
Reliability is the probability that a product
will perform its function under normal use
for a specific period (product life span).
Reduce the number of components in a
product
Reduce complexity in component design
Use standard and proven components
Ensure damage free shipping and
predictable service
 Design for X-
Design for Maintenance & Serviceability

Product maintenance is an important

aspect to be taken during design.
Products should be simple and easy to
maintain.
Part replacement requirements, spare
part needs, spare part availability.
Easy Access for part replacement.
Part interchangeability between models
Self diagnosis (Laser Printer,lamp holder)
 Design for X-
Design for Logistics and Handling
logistics is the process of planning ,implementing
and controlling the transfer and storage of goods
from point of origin to point of consumption
Handling means orientation, holding, positioning,
transferring or transporting
Design for seamless transportation.
Optimal packaging to save space and damage.
Provision for product handling with safety.
Provide handling and logistics information on body
part or cover
Provide rollers, castors or handles
 Design for X-
Design for Disassembly[DFD]

Is a process in which the designer

intentionally incorporate some features so
that access various parts for dismantling
Design for easy disassembly.
No welded joints
No dissimilar materials joined together.
Common materials as far as possible.
Automated disassembly
 Design for
Recycling[DFRc]
Design paradigm by which a product
and all the supporting phases for
manufacturing and service of the
product are designed such that
materials involved can be recycled or
reused.
Easy cleaning.
Handling of dangerous materials
Minimize no of different materials
Try to avoid moulded in metal inserts or
reinforcements in plastic parts
 Design for Re
Engineering
Systematic engineering process to
re- invent or re-develop a product to
address specific issues
lead to development of a new
product or revamping of an existing
product
 Steps involved in re-engineering
1. Define element to re-engineered
2. Define customer requirement
3. Determine the benchmark performance to be obtained
4. Determine the shortcoming in existing
5. Identify the root cause of the short coming
6. Develop multiple solutions by brain storming
7. Evaluate the solutions and choose appropraite one
8. Implement solution to develop a revised element
9. Implement revised element
10.Monitor the performance an use the information for
continues improvement
 Design for X-
Design using Group Technology.
In Group Technology Parts are
grouped based on their similarity in
design attributes and manufacturing.
Such parts form a family or a group.*
By grouping similar parts a single
manufacturing solution can be used.
This reduces the cost.
 Design requirements of
rocket shell
Rocket shell is outer case of rocket
also known as rocket motor case
Part is having cylindrical form
Size can be around 1.5 to 3 m dia
and 5 to 8m long
Part undergoes various complex
situations during its production as
well as application
Design consideration of rocket shell

Design for strength

Part must have to withstand shock , thrust load
and pressure variation inside and outside the
shell
Designed for an aerospace standard factor 1.5
for ultimate strength and 1.15 for yield strength
Design for handling
Fabricated in one location ,assembled in another
location and launched from a launch pad
Requires lot of transportation and handling
 Design for reliability
Very complex product
Involves lot of time ,energy and cost for
development
Must be designed for reliability
Design for manufacturing
Lot of manufacturing process such as
rolling , forming, welding, machining etc.
For effective manufacturing of the item ,it
must be designed for manufacturing
 Design for assembly
Design must facilitate easy assembly process
bcz many parts are to be integrated in
construction
Design for saftey
Involves lot of complex and hazardous situations
Design for quality
Design cannot compromise on the quality of
shell
If compromised entire design will be affected