Multidisciplinary Minor :Product Design and Manufacturing

Manufacturing Process and

Manufacturing Design
Prepared By: Vandana Kotak
 Course Outcomes
1. Understanding fundamentals of design and manufacturing, and
computer aided tools
2. Apply visual and value engineering principles
3. Analyse material selection and manufacturing & maintenance
processes
4. Develop and apply costing strategies
• Selection of manufacturing processes
• primary manufacturing processes, secondary manufacturing
processes, tertiary manufacturing processes,
• design for manufacturing
• Design review
• DFM & DFA principle
• manufacturing guidelines
• Computer aided design
• Design for Assembly
Casting
Design for manufacturing (DFM)
• Definition
• Design for manufacturing (DFM) is a design technique for manufacturing ease
of an assortment of parts that would constitute the final product after
assembly.
• Design for manufacturing focuses on minimizing the complexities involved in
manufacturing operations as well as reducing the overall part production cost.
• Design for Manufacturing is also the process of proactively designing
products to:
1. Optimize all the manufacturing functions:
• fabrication
• assembly,
• Test
• procurement
• Shipping
• Delivery
• Service
• repair
• 2. Assure the best
• Cost
• Quality
• Reliability
• Tegulatory compliance
• Safety
• Time-to-market
• Customer satisfaction
Design Review
The purpose of a design review is:
• to provide a systematic and thorough product-process analysis,
• a formal record of that analysis
• feedback to the design team for product and process improvement
Some commonly associated problems with the implementation of the design
review process are:·
• Unevenly matched skills and knowledge among the design review team
• Lack of communication between product developers and the related departments
• No time to make design-review-based changes
• Lack of design review experience.
• Each department considers design review a separate stage and not included in the
initial design process.
Design Review
• Soft-Hard Review:.
• The soft-hard (SH) review addresses the need to design a product for safety,
that is, in terms of the real-world conditions.
• The soft reviews look into the careless misuse of products by users, beyond
normal wear and tear.
• Failure Mode and Effects Analysis
• The basic method is to describe the parts of a system and list the
consequences if each part fails
• In most formal systems, the consequences then are evaluated by this criteria
and associated risk indices:
• severity (S)
• likelihood of occurrence (O)
• probability of occurrence (P)
• inability of controls to detect it (D)
Design Review
• Experimental Design
• The objective is to determine those variables in a process or product that form
critical parameters and their target values
• By using formal experimental techniques, the effect of many variables can be studied
at one time.
• There are six basic steps of the same-
1. Establish the purpose.
2. Identify the variables.
3. Design the experiment.
4. Execute the experiment.
5. Analyse the results.
6. Interpret and communicate the analysis.
Why DFM?
• The DFM methodology allows for new or improved products to be
designed, manufactured and offered to the consumer in a shorter
amount of time.
• DFM helps eliminate multiple revisions and design changes that cause
program delays and increased cost.
• With DFM the design is often more comprehensive, efficient to
produce and meets the customer requirements the first time.
How to Perform DFM?.
• Many companies today are integrating the DFM and DFA practices through
design and manufacturing teamwork.
• The Design for Manufacturing (DFM) and Design for Assembly (DFA)
techniques are two different classifications.
• DFM techniques are focused on individual parts and components with a
goal of reducing or eliminating expensive, complex or unnecessary features
which would make them difficult to manufacture.
• DFA techniques focus on reduction and standardization of parts, sub-
assemblies and assemblies.
• The goal is to reduce the assembly time and cost.
Design for Manufacturing guidelines:
Minimize number of components:
• Assembly costs are reduced.
• The final product is more reliable because there are fewer connections.
• Disassembly for maintenance and field service is easier.
• Reduced part count usually means automation is easier to implement.
• Work-in-process is reduced, and there are fewer inventory control problems.
• Fewer parts need to be purchased, which reduces ordering costs.
Use standard commercially available components:
• Design time and effort are reduced.
• Design of custom-engineered components is avoided.
• There are fewer part numbers.
• Inventory control is facilitated.
• Quantity discounts may be possible....
Design for Manufacturing guidelines:
Use common parts across product lines:
• There is an opportunity to apply group technology.
• Implementation of manufacturing cells may be possible.
• Quantity discounts may be possible.
Design for ease of part fabrication:
• Net shape and near net shape processes may be feasible.
• Part geometry is simplified, and unnecessary features are avoided..
• Unnecessary surface finish requirements should be avoided;
otherwise, additional processing may be needed.
Design for Manufacturing guidelines:
Design parts with tolerances that are within process capability:
• Tolerances tighter than the process capability should be avoided; otherwise,
additional processing or sortation will be required.
• Bilateral tolerances should be specified.
Design the product to be foolproof during assembly:
• Assembly should be unambiguous.
• Components should be designed so they can be assembled only one way.
• Special geometric features must sometimes be added to components to achieve
foolproof assembly.
Minimize use of flexible components:
• Flexible components include parts made of rubber, polymer, gaskets, cables, etc.
• Flexible components are generally more difficult to handle and assemble.
 What is Assembly Process ?
• Assembly of a product is a
function of design
parameters that are both
intensive (material
properties) and extensive
(physical attributes) in
nature. Examples of such
design parameters include
but are not limited to
shape, size, material
compatibility, flexibility,
and thermal conductivity.
 What is Disassembly Process ?
Disassembly is the organized
process of taking apart a
systematically assembled product
(assembly of components).
Products may be disassembled to
enable maintenance, enhance
serviceability and/or to affect end
of life objectives, such as product
reuse, remanufacture, and
recycling.
Design for Assembly
• Design for assembly (DFA) seeks to simplify the product so that the
cost of assembly is reduced. Consequently, applications of DFA
principles to product design usually result in improved quality and
reliability and a reduction in production equipment and part
inventory. It has been repeatedly observed that these secondary
benef its often outweigh the cost reductions in assembly.
Design for Assembly
Different Methods of Assembly

• Manual assembly - It involves

parts that are transferred to
workbenches, where the
assembly of individual
components into the final
product takes place. Hand
tools generally are used to aid
the worker for easy assembly.
Automatic assembly: This
method uses either synchronous
indexing machines and part
feeders or nonsynchronous
machines, where parts are
handled by a free transfer device.
Design of Assembly
• Fixed or hard automation: Fixed or hard automation characteristically
involves a custom-built machine that assembles only one specific
product and entails a large capital investment.
• Robotic Assembly : This can take the form of a single robot or a multi
station robotic assembly cell with all activities simultaneously
controlled and coordinated by a PLC (Programmable Logic Controller)
or computer.
Design for Assembly Guidelines
Manual Assembly :
• Ensure good product accessibility as well as visibility.
• Eliminate the need for assembly tools or special gauges by designing
individual components to be self, self-aligning and self self-locating.
• Minimize the total number of individual parts, if possible. To facilitate
this objective, multipurpose components may be used.
• Eliminate excess parts and combine two or more parts into one, if
functionally possible.
• Avoid or minimize the need to reorient the part during the assembly
process. Ensure that all insertion processes are simple.
Design for Assembly Guidelines
Automatic Assembly :
• Avoid the possibility of parts tangling, nesting, or shingling during feeding,
since this can complicate and unduly delay the assembly process.
• Avoid reorienting assemblies, as such moves may require a separate
workstation or machine, thereby increasing costs.
• Design parts to ease automation by presenting or admitting parts to the
assembly machine in the right orientation after the minimum possible time
in the feeder.
• Design parts with a low center of gravity, thereby imparting in them a
natural tendency to be fed.
Robotic Assembly :
• Many robot manipulators have poor repeatability; there fore, features
such as lips, leads, and chamfers assume a great deal of importance.
• Design components such that all can be gripped and inserted using
the same robot gripper.
Methods for evaluating design for assembly
• Some of the evaluation methods for assembly are:
• The Hitachi assembly evaluation method.
• The Lucas DFA method.
• Method based on Method Time Measurements (MTM) Standards.
• The procedure follows the steps
below:·
• Product design specification.
• Product analysis.
• Functional analysis (first Lucas
analysis);loop back to step 2 if the
analysis yields problems.
• Feeding analysis (second Lucas
analysis).
• Fitting analysis (third Lucas analysis).
• Assessment.
• Return to step 2 if the analyses
identify problems.
 Method based on Method Time
Measurements (MTM) Standards
Various factors are taken into in n improved methodology, such as:
• weight, size, and shape of components being assembled;.
• frequency of assembly tasks (based on number of similar products
being assembled within a particular timeframe);
• personnel requirements;
• postural requirements;
• material handling requirements; and
• need for component preparation.
• consideration
Design for Disassembly
• Definition: In the modern era of environmental awareness, end-of-life
objectives, such as component reuse, remanufacture, and recycling
constitute some of the most important reasons for disassembling
products.
• This can be attributed to the staggering impact of industrial and
domestic waste on the environment.
Depending on the extent of disassembly, non destructive disassembly can
be further classified into two categories:
Total disassembly:· Disassembling of product is done into its constituent
components.
• This may not be economically feasible due to the imposition of external
constraints, such as time, economic factors, and presence of hazardous
materials.
Selective disassembly:· Selective disassembly is the reversible dismantling of
complex products into less complex subassemblies or single parts.
• It involves the systematic removal of desirable constituent parts from an
assembly while ensuring that there is no impairment of parts due to the
process.
Disassembly Process Planning:
Stages of disassembly process plan(3 stages ):
1. Product analysis:
• It consists of assessing the end value to be realized by disassembling
the product.
• Disassembly value comprises the potential of the product to be
reused, its value to be recovered, risk potentials as well as existing
recycling technology.
2. Assembly analysis:·
• It is essential to understand how a product has been put together in order
to take it apart.
• This planning consists of determining the
• tooling requirements,
• magnitude of force
• time and personnel
• knowledge of functionally more valuable components.
3. Usage, mode, and effects analysis:
• As most products are disassembled after they have been put to actual use,
they have been subjected to considerable wear and tear.
Design for disassembly Guidelines
• To minimize assembly work.
• Similar elements need to be combined in a group.
• Material variability should be minimized to predict disassembly
procedures with a degree of certainty.
• As far as possible, compatible materials should be used to facilitate
disassembly.
• Any harmful materials, if functionally important, should be grouped
together into subassemblies for fast disposal.
• Any valuable, reusable, and harmful parts need to be easily
accessible. This saves a lot of time and effort trying to reach the part
in question.
• Achievement of predictable product configuration.
• Aging and corrosive material combinations need to be avoided, since
disassembling them cleanly and efficiently (due to their tendency to
corrode, spread corrosion, and break off inside the product) often is
difficult.
• What is said in the preceding point holds equally true as far as
protecting subassemblies from corrosion, the reasons being the
same.
 Product Recovery Approach
• The objective in the
product recovery is
to recover as much
as possible of the
economical as well
as ecological value
of products,
components, and
materials, so as to
minimize the
ultimate quantities
of waste.
Product Recovery Approach
Disassembly Sequence Planning (for Product Recovery)
• A Disassembly Sequence Plan (DSP) is a program of tasks that begins
with a product to be disassembled and terminates when all the desired
parts of the product are disconnected.
• A DSP aims to optimize product recovery through.
• the minimization of cost,
• maximization of material recovered, and
• minimization of disassembly time.
• A DSP use mathematical techniques such as linear programming,
dynamic programming, and graphical tools.
Product Recovery Approach
Disassembly Sequence Planning (for Product Recovery)
Three distinct types of geometric assemblies can be defined:
Type I:
• An assembly having a main component to which other components or
subassemblies are directly or indirectly assembled.
Type II:
• An assembly having no main component. All components are assembled
with others. This can be disassembled only as a single component.
Type III:
• An assembly that is a combination of both of these types. This can be
disassembled as further components.
Product Recovery Approach
Disassembly Sequence Planning (for Product Recovery)
• Three kinds of sequences, driven by disassembly cost, are analyzed on
formation of the disassembly tree:
Type I (target disassembly sequence):·
• Specific components are disassembled to remove valuable components.
Type II (optimal disassembly sequence):.
• Disassembly is stopped when marginal return on the operation becomes
uneconomical.
Type III (complete disassembly sequence):·
• Complete disassembly of the product.
Product Recovery Approach
Disassembly Sequence Planning (for defective parts in a product).
• Changes in DSPs have to be incorporated to handle factors leading to
uncertainties.
• Availability of original CAD drawings and an unchanged product
structure has been assumed.
• The physical relationships among components is represented using
the disassembly precedence matrix developed from the original CAD
model of the product using the AND, OR, and OR/AND relationships.
• Next, an optimum disassembly sequence plan is generated.
Disassembly Sequence Planning (for defective
parts in a product)
Evaluation of Disassembly Planning
• Disassembly costs must be justified by the economic advantages of
recycling.
• Recycling costs and benefits differ for specific fractions of recovered
materials.
Reasons for NOT Implementing DFMA
• Not Invented here
• No time
• The Ugly baby Syndrome
• Low Assembly Cost
• Low Volume
• The database Doesn’t apply to our Product
• We’ve been doing it for years
• It’s only value Analysis
• DFMA is one among the many technique (DFQ or DFC)