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DFMA
DFMA
J.JAYARAMAN
TECHNOLOGY
DEVELOPMENT INTEGRATION DEMONSTRATION PRODUCTION
KNOWLEDGE
KNOWLEDGE KNOWLEDGE
POINT 1
POINT 2 POINT3
PROGRAM
LAUNCH PRODUCTION
TECHNOLOGIES CAN MEET
AND RESOURCES COST
DESIGN PERFORMS SCHEDULE
MATCH
AS EXPECTED AND
REQUIREMENTS
QUALITY
TARGETS
ATTAINMENT OD DESIGN AND
MANUFACTURING KNOWLEDGE
WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL MFG. PROGRAM
PRIOR TO MFG. PROCESSES IN CONTROL EXPERIENCE
AT PRODUCTION
BEST PRACTICE
AT LEAST 90% DWGS. ALL CRITICAL MEET COST &
COMPLETED PROCESSES SCHEDULE
IN STATISTICAL TARGETS
CONTROL
8 SCREWS TO NO
SCREWS
DFMA METHOD
OF ELIMINATING ASSEMBLY
FASTENERS OPERATIONS
FROM 83 TO
54
TOTAL ASSY.
TIME 592SEC.
TO 277 SEC.
RIBBON BASEPLATE
DIABLO PRINTER
OLD DESIGN 77 PARTS
NEW DESIGN
36 PARTS
COMPARISON OF ORIGINAL
NEW DESIGNS OF RETICLE
ASSY.
OPTION 1
PILOTS INSTRUMENT
PANEL
OPTION 2
PILOT’S INSTRUMENT
PANEL
ORIGINAL PANEL NEW PANEL
( OPTION 1 )
PARTS COUNT 74 9
FABRICATION TIME HRS. 305 20
ASSY./INSTALLATION TIME HRS. 149/153 8/153
TOTAL TIME HRS. 697 181
WEIGHT KG. 3.0 2.74
COST $ 56000 15000
Advantages of DFMA
Typical results of DFMA application
Results of 88 published case studies
Decreases
51% parts count reduction
37% parts cost
50% time to market
64% in assembly time
57% in manufacturing assembly time
58% in assembly operations
69% in separate fasteners
68% in assembly defects
57% in service calls
68% in improvement in quality and reliability
Benefits of DFMA
Shorter developmental schedules and reduced
cycle times.
Better first article quality
Development of robust product designs
Easier transition of designs to production
Better supplier product integration
More effective risk management
McDonnel Douglas experience
Reduce number of parts and fasteners used on aircraft
It means fewer opportunities for defects
For each fastener there is the chance that the hole will be
drilled in the wrong place or be the wrong size
By reducing the number of fasteners – numbers of defects
reduced, therefore, produce a higher quality product
Weight is critical. Fuel costs approximately $50,000 per
pound of aircraft weight over 6000 hrs of the life of the
aircraft
There are 179000 on the FA-18 CD fasteners
In previous models several parts were made of sheet metal
because machined parts were unable to reach minimum
gage limits
With high speed machining – thinner gauge limits have
become possible
ACCELERATION SENSING ASSEMBLY
OPTION-I OPTION-II
COMARISON TABLE ASA OPTIONS
PARAMETER OPTION - I OPTION - II
DESIGN AXIOMS
DFM GUIDELINES
TAGUCHI METHOD
DESIGNERS TOOLKIT
GROUP TECHNOLOGY
FMEA
VALUE ANALYSIS
DFM METHODOLOGY COMPARISON (CONTD)
KEY TO DISADVANTAGES
KEY TO ADVANTAGES A. INTERPRETATION NOT ALWAYS SIMPLE
A. NARROW RANGE OF POSSIBILITIES B.. REQUIRES “BUY IN” ON PART OF USER
B. RESULTS IN INHERENT ROBUSTNESS C. EXCEPTIONS ARE NOT INDICATED
C. READY REFERENCE TO BEST D. RATES ONLY EASE OF ASSY.DOES NOT
PRACTICES ADDRESS PART HANDLING OR OTHER
D. EMPHASISES EFFECTS OF RELATED MFG. PARAMETERS
VARIATIONS E. DEVELOPMENT REQUIRES INPUT FROM
E. HELPS IDENTIFY AND PRIORITIZE EXPERIENCED EXPERTS FAMILIAR WITH
CORRECTIVE ACTION SPECIFIC PROCESS CAPABILITIES AND
F. PROVIDES BOTH GUIDANCE AND NEEDS
EVALUATION F. TO BE USED ON A REGULAR BASIS
G. CAN SHORTEN DESIGN /TOOLING IMPLEMENTATION MUST BE USER
CYCLE FRIENDLY
H. CAN REDUCE TOOLING AND G. MUST BE DEVELOPED AND/OR
FIXTURING COST CUSTOMISED FOR EACH SPECIFIC
APPLICATION
H. OFTEN REQUIRES DIFFICULT TO OBTAIN
KEY TO APPLICATIONS INFORMATION
A. MECHANICAL AND ELECTROMECHANICAL DEVICES AND ASSEMBLIES
B. ELECTRONIC DEVICES AND SYSTEM
C. MANUFACTURING AND OTHER PROCESSES
D. SOFTWARE INSTRUMENTATION AND CONTROL SYSTEM INTEGRATION
E. MATERIAL TRANSFORMATION PROCESSES
F. SPECIFIED AND OR UNIQUE MANUFACTURING FACILITIES SUCH AS
FLEXIBLE ASSEMBLY SYSTEMS
DFMA application areas
DFMA has been applied successfully to
Structural design
System design
Landing gear system
Flight controls
Electrical, electronic hydraulic systems
Environment controls
COST AND EASE OF MODIFICATIONS
BENIFITS OF IMPROVED ASSY.
DESIGN CONCEPT
SUGGESTIONS FOR
DESIGN FOR ASSEMBLY SIMPLIFICATION FOR
( DFA ) PRODUCT STRUCTURE
SELECCCTION OF
SUGGESTIONS FOR
MATERIALS AND
MORE ECONOMIC
PROCESSES AND EAZRLY
MATERIALS AND
COST ESTIMATES
PROCESSES
PROTOTYPE PRODUCTION
BDI software
It does an assembly analysis profile on a standard format where it theorizes the
number of tasks to be performed, fasteners required, connectors to be installed,
candidates for elimination, acquisition of items not in reach or in stock,
requisition of tools not in hand, standard operations, library of operations and
recommendations.
All these activities are numbered and plotted. It automatically provides
suggestions for improvement.
System provides suggestions for design and indicating every task with its time
saving and its percentage reduction. It indicates specific instructions to
perform the related tasks in order to obtain the suggested savings.
It also lists design for assembly analysis totals all parameters used for analysis
such as total assembly time, totally assembly cost, total assembly weight,
number of parts, sub assemblies theoretical minimum numbers of parts or
unanalysed sub assemblies and the hourly labour rate.
All suggestions and comments included in the computer generated tables are
automatically provided to aid the designers and manufacturing engineers to
obtain a better view of the job
Questions asked in DFMA about
each part in a product design
Does the part move with respect to other parts
already assembled
Must the part be made from a different material
or isolated from all other parts already
assembled
These questions lead the reviewers to re-
evaluate each part and process that has been
specified
If a part does not meet any of these criteria – it is
a candidate for elimination or consolidation with
another part
Results of Design for Assembly (DFA) Analysis for the Motor Drive
Assembly Redesign
TYPICAL FUNCTIONAL
FLOW
1.3.2.1.1 1.3.2.1.2
CHARGE STORAGE 1.3.2.1.3
RECEIVE PULSE
CAPACITOR DISCHARGE CAPACITOR
INITIAE SIGNAL
THROUGH LASER DIODE 1
1.3.2.1.4
1.3.2.1.6 1.3.2.1.5 CREATE LASER
TRANSMIT PULSE CREATE LASER PULSE ENERGY.
THROUGH LENS PULSE SHAPE
TYPICAL PROCESS FLOW
P 1.1
PRODUCE ACTIVE
TRANSMITTER
P 1.2
PRODUCE ACTIVE
RECIEVER
P 1.6
P 1.3 AND P 1.7
ASSEMBLE INTO
AND PRODUCE PASSIVE PRODUCE LOWER
UPPER HOUSING
RECEIVER HOUSING ASSEMBLY
ASSEMBLY
P 1.4
PRODUCE FLEX.
ASSEMBLIES
P 1.3.4
P 1.3.1 P 1.3.2 P 1.3.3 PICK AND PLACE
CODER CLEAN BOND WIRE BOND PbSe
ATTACH PADS CODER INTERCONNECT
STANDOFF
P 1.3.2
CLEAN BOND PADS
P 1.3.6 P 1.3.5
INSPECT WIRE BOND
PbSe
ACTIVITIES TO ACHIEVE
MFG. KNOWLEDGE
IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL
MANUFACTURING PROCESSES
DETERMINE PROCESS IS IN CONTROL AND CAPABLE
CONDUCT FMEA
SET RELIABILITY GROWTH PLAN AND GOALS
CONDUCT RELIABILITY GROWTH TESTING
CONDUCT REVIEW TO BEGIN PRODUCTION
Contd..
BEST APPROACH TO
PRODUCT DEVELOPMENT
SYSTEM
TECHNOLOGY PRODUCTION
INTEGRATION & DEMONSTRATION
DEVELOPMENT
TECHNOLOGY MATURITY
DESIGN MATURITY
PRODUCTION MATURITY
CONCLUSION