DFMA Case

Study
-Kaviprakash V
-AM.EN.U4ME18027
Optimization Environmental Impact by Integrating
DFMA Approach: A Case Study of Measuring Tape
• The mechanism allowed the tape at any point to be stopped and then held while a button
triggered the spring, which sent the spring back to the case.
• These tapes shaped as steel coiled tape in a plastic or metal casing with a coiled spring
placed within a coiled tape to provide a biasing capacity that is able to recuperate and
rewind the tape inside the package automatically.
• ABS has three monomers, which are acrylonitrile, butadiene, and styrene.
• ABS plastic has useful properties, including thermal strength, lightweight, and simple
formability.
• It is essential to explore the recycling of ABS to minimise environmental, climate, and
energy problems.
Methodology
• The data collection is gained from the questionnaire. The
questionnaire is conducted through Google Form.
• The questionnaire is used to collect information from the user and to
identify the satisfaction level when using measuring tape because
every data and information is considered as problems that need to be
solved.
• Analysis and interpretation of data from the questionnaire are
important to develop a new design.
Cad design and analysis
• After selecting the design concept, the final design was then
transformed into a CAD part using Catia V5 software.
• Finite Element Analysis (FEA) is used the displacement on many
improvement sections that occur by applying some force in
recognition of the maximum and minimum of Von Mises stress.
Dfma approach
• The results are from the DFMA approach using the CAD model, and the
contrast carry out between the sustainable, finite, and cost analysis for existing
and upgrades designs.
 The difference between the quantity aspect and the current design is
smaller.

The latest design comprises 11 components, while the current

Dfma
component consists of 15 components.

approach The latest concept assembly time is 72.80 seconds lower than that of
95.15 seconds.

result The new design is 45.23 percent efficient, based on a comparison of

the performance of the DFA, showing that a new design has
increased assembly efficiency and the ability to decrease the costs,
time, and quantity component. 

The result is that RM0.56 is cheaper than the current RM 0.59

design.
Dfs and dfe analysis
• newly improved construction with new material (PB) has a smaller environmental impact than current
designs since the figures show a weight reduction of approximately 10%, a carbon footprint of around
10%, water eutrophication of 30%, acidification of air of 7% and total energy of approximately the same.
conclusion
• This study shows that using these two methodologies would yield
better results for goods that are environmentally friendly.
• The two approaches were analysed to determine the effects of the
redesign of the assembly and manufacturing system and the product’s
sustainability, utilising the existing design, and improved design.
• Thus an environmentally sustainable product can be suggested by the
improved nature.
Integrating DFMA to Sustainability and FEA
Assessment: Case Study of Portable Bluetooth Speaker
• Nowadays, Bluetooth speakers have become one of the most significant audio
equipment roles for computer users, mobile phone users, and home entertainment
audio appliances with 2.4 GHz frequency to enabling the devices.
• They realized that Bluetooth is a useful technology utilizing air interface to make
pairing accessible between devices. It helps to shorten the time and human efforts for
transferring data.
• . Furthermore, it can use a portable or fixed device because of its portability, enabling
it to quickly and effortlessly listen to music on the move anytime and anywhere.
• In this study, the DFMA method and sustainable analysis are used to optimize the
assembly process and environmental impact.
Meth0dology
• DFMA helps consumers to purchase the desired goods with the same feature as the
original but at lower manufacturing costs.
• The environmental factor evaluation is also performed using SolidWorks@ software
to test the environmentally friendly product to be environmentally, socially, and
economically advantageous.
• The collection of materials is a critical component of the design. It provides several
ways to reduce the effects of the climate.
• The materials used have a significant impact on the environmental performance,
impacting its energy efficiency in manufacturing and use, how effectively it can be
recycled or if they pose a risk if disposed of at last.
DFA Analysis
• The new design consists of 16 components, while the original component consists
of 28 components.
• The time to assemble the new design is 87.69 seconds below 154.96 seconds.
• The result is 0.73 RM cheaper for the new design than the original 1.29 RM.
• the new design is now fully improved 31% of design efficiency; the result indicates
that the new design is more cost, time, and quantity-saving in its assembly phase.
• The result is that the new Aluminum Alloy 6061 material improvement design is
smaller than another production cost. The price for the latest design upgrade only is
RM 20,22 for both. The cost of the current design is reduced by 45.20%.
Dfs analysis
• The latest enhanced design has a greater environmental effect than the current design,
provided that data indicate an improvement from 131.5418 g to 399.1613 g in weight, an
increase in carbon footprint from 1.2 kg of CO2 to 7.8 kg CO2; an increase in water
eutrophication from 8.24x10-4kg PO4e to 3.0x10-3 kg PO4e; an increase from 0.0053 kg
SO2 to 0.035 kg Acidification in air.
• Although the carbon footprint, air acidification, water eutrophication, and energy
consumption of Aluminium Alloy 6061 are higher than Acrylonitrile butadiene styrene
(ABS), it does not means that Aluminium Alloy 6061 is worse material to produce this
product.
• In terms of material strength, Aluminium Alloy 6061 is more endurance than Acrylonitrile
butadiene styrene (ABS). Thus, it can makes the life span of the product longer.
conclusion
• According to the sustainability analysis conducted, it can be concluded that
material selection to producing a product is essential.
• It is because each material has different characteristics and properties that can
have an impact on the environment.
• The current and enhancement design was evaluated for both methodologies to
identify the outcomes of the re-design comparison of the assembly and
development concepts and the product’s sustainability.
• The design change may, therefore, mean an environmentally friendly product.