PRODUCT
LIFECYCLE
MANAGEMENT
P R E S E N T ATI O N
D AT E : M A R C H 0 9 , 2 0 1 6
DESIGN FOR
ASSEMBLY (DFA)
OMKAR PRADEEP KHANVILKAR (ME-231)
BRIEF
Introduction
Definition
Comparison of Assembly Methods
Benefits of DFA
Methods of DFA Analysis
Case Study
INTRODUCTION
Definition
Ease of Assembly
Assembly Methods
Manual Assembly
Fixed or Hard Automation
Soft Automation or Robotic Assembly
Benefits
Fewer Parts
Reduction in Assembly Time & Cost
Reduction in Total Product Cost
METHODS OF DFA ANALYSIS
Hitachi Method: The Hitachi Assembly Evaluation Method (AEM);
Boothroyd & Dewhurst Method: The B&D - DFA Evaluation Method;
Lucas DFA Method: The Lucas DFA Evaluation Method.
C A S E S T U DY
Lucas Method to design
Automotive Fuel Intake
Cover
CASE STUDY
1.
Rivet: allows the rotation of the fuel cover, before the
DFA analysis union of 4, 5, 6 e 7 parts with part 3.
2.
Double action torsion spring, keeps the fuels cover
open during the feeding procedure, and facilitates its
closure.
3.
Fixed hinge, fixes the fuel cover to the car body.
4.
Movable hinge, allows connection between 5, 6 and 7
parts with 1;
5.
External cover
6.
Internal cover allows plastic lock attachment and
increases fuel intake cover stiffness.
7.
Plastic lock, allows electrical or manual locking of the
fuel cover, depending on the car version.
CASE STUDY
Assembly Functional Analysis before DFA of part
4
Feeding analysis for part 4 before DFA
CASE STUDY
Fitting analysis for part 4
CASE STUDY
The mobile interface increases in order to allow
the direct union with the external cover.
The external cover thickness was increased to
support the new structural requirement.
The flange at the external cover was changed to
allow electrical resistance spot weld.
The plastic lock was changed for a new metal
one assembled also by spot weld.
The hemming process was replaced with a spot
weld.
The riveting force over the rivet was changed to
increase the friction between the mobile and
fixed interfaces.
CASE STUDY
CASE STUDY
Performance indexes for the fuel intake cover
Before
After
CASE STUDY
Performance indexes for all parts of the fuel intake cover after DFA
application
SUMMARY
DFA is a powerful tool for product development, since the conceptual phase
of the product development.
An efficient application of its statements allow gains in terms of reduction in
the number of parts necessary, without compromising the functionality of
the product, and also allows a cost reduction, and in many cases an
improvement in the product quality.
REFERENCES
Websites:
[Link]
[Link]
https://
[Link]/3734072/Product_Design_Improvement_by_Design_for_Assembly_DFA_Method_A_Ca
se_Study_on_Steam_Iron
Notes:
Design for assembly case: automotive fuel intake cover, Open Access Library, Volume 6 (12) 2012
me349_dfa_lecture_notes.pdf, Wise
Design for assembly : a critical methodology for product reengineering and new product development,
Mohan V . Tatikonda, CFPIM
THANK YOU
