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Case Study One: Corner

Table
BY LIAM SMYTH
GMIT LET TERFRACK

Introduction

Product: A (Non-DFM designed


Corner Table)

Product: B (DFM designed Corner


Table)

PRODUCT A

PRODUCT A: Overview
Product A is designed to the same criterial as a standard corner table
Simple square design with the introduction of rounded edges to remove the square feel and
sharpness of the table.
Product A requires a number of processes to be completed during its manufacturing.
The design has been completed without any consideration given to Design for manufacture
There are a number of disadvantages to the non use of Design for Manufacture
1. Increased lead, production and set up time
2. More processes required to complete the table
3. More expensive on manufacturer and consumer
Product A will be now explained broken down in terms of the Design for Manufacture principles that have
not been applied

Design for Manufacture: Breakdown


Product A (Standard Corner Table)

Principle One Not Applied


First principle not applied: Minimise the Total Number of Parts and Subassemblies
Total of 13 Number of Parts
Three sub-assemblies used in its creation
Disadvantages of not using this principles:
1.

Large amount of material required

2.

Complexity in assembling the table (Three sub-assemblies)

3.

Increased Labour cost

4.

Longer lead time

Sub-assembly one & two

Sub-assembly three

Principle Two Not Applied


Second principles not applied: Use Standard Components & Design Parts for Multi-Use
Three different rails used throughout the table

All top rails consist of the same dimensions. Bottom rails vary in widths.
Different processes required for all components
Disadvantages of not using this principles:
1.

Various in components size (No standard component)

2.

Complexity in assembling the table

3.

Require different processing (three different rails)

4.

Longer set up times

5.

Increased Labour cost

Top Long & Short Rail

Bottom Long & Short Rails

Principle Three Not Applied


Third principle not applied: Ease of Fabrication Linked due two the previous two principles not
used
Variation in material Dimensions has made the fabrication of part more complex
Requirement for machines to altered to accommodate components design, e.g. Two different legs
required to be mortised to cater for table design
Due to the offset in the bottom rails of the table
Disadvantages of not using this principles:

1.

Harder to manufacture Product B in Mass production

2.

Increased number of processes along with set ups

3.

Increased Labour cost

4.

Limited Product Flexibility

5.

Longer lead and set up time

Variation In Rail Dimensions

Bottom Rail Offset

Conclusion of Product A
Evident no consideration given to Design for Manufacture principles
Difficult and complex to manufacture and assemble with its current design
Non-practical to mass manufacture this product, due to impractical methods of fabricating parts
Relatively high lead, set up and manufacturing time associated with this product
Advantages of using the principles identified above:

1.

Reduction in lead, set up and manufacturing time

2.

Easier to manufacture and repeatability of product A (Mass production of product would be


Viable)

3.

Reduction in manufacturing cost, with increase in profits

PRODUCT B

PRODUCT B: Overview
Product B is designed with the use of Design for Manufacture principles
Relative new and modern design with the incorporation of curves to increase aesthetics of
Product B
Product B requires a limited number of processes to manufacturer the table.
The design has been completed with the total use of Design for Manufacture
There are a number of advantages to the use of Design for Manufacture
1. Reduction in lead, production and set up time
2. Less processes required to complete the table
3. Ease of fabrication and repeatability
4. Less expensive to the manufacturer and consumer
Product B will be now explained broken down in terms of the Design for Manufacture principles that have
been applied

Principle One Applied


First principle applied: Minimise the Total Number of parts & Subassemblies
Total of seven parts, six less than product A

Reduction in the complexity and confusion of assembling of Product B


No sub-assemblies required in Product B
Advantages of using this principles:
1.

No sub-assemblies required

2.

Reduction in confusion or complexity in assembling/placement of parts

3.

Reduction in Labour cost

4.

Short lead time

5.

Reduction in the amount of material required

Minimise the Total Number of parts &


Subassemblies

DFM Corner Table Assembled & Dis-assembled

Principle Two Applied


Second principle applied: Develop a Modular Design
Variation in Products B table top

Can have either a round or square table top with base remaining the same
No additional processes or parts required
Advantages of using this principles:
1.

Still allows ease of fabrication

2.

Does not increase the processes require to manufacture different tops

3.

Labour cost remain the same

4.

Product Flexibility

5.

Lead time remains the same

Develop a Modular Design

Principle Three Applied


Third principle applied: Use Standard Components
The leg is a standard component throughout Product B

Ease of replacement if leg becomes damaged


Ease of fabrication and repeatability as only requires one process
Advantages of using this principles:
1.

Ease of fabrication and repeatability

2.

Common component throughout Product B

3.

Ease of Replacement if leg becomes damaged

4.

Component Flexibility to used throughout the same product

5.

Lead and set up time remain the same

Use Standard Components

Rendered and Scale Model of DFM Table with Standard Component Displayed

Principle Four Applied


Four principle applied: Design Parts for Multi-Use Linked with the previous principles used
The leg is a common component throughout all table variations

Used in a total of three different table designs


Leg provides foundation amongst all tables
Advantages of using this principles:
1.

Ease of Replacement if leg becomes damaged

2.

Ease of fabrication and repeatability

3.

Single process required to manufacture Leg component

4.

Component Flexibility throughout the use in a number of tables

5.

Lead and set up time remain the equal

Design Parts for Multi-Use

Scale Models of the Various Table Designs with the Leg


commonly used throughout.

Principle Five Applied


Fifth principle applied: Design Parts for Ease of Fabrication
Use of common component throughout Product B

Two machines required to create the table, however only one needed to manufacture Product B
Limited processes required to create Product B
Advantages of using this principles:
1.

Ease of repeatability due CNC use

2.

Processes along with set ups remain equal throughout its product

3.

Ease of mass producing Product B

4.

Reduction in labour cost and time

5.

Short lead and set up time

Design Parts for Ease of Fabrication

Both DFM Designed Products Cut on Laser.


Due to CNC availability a full size product could
not be manufactured during these tutorials.

DFM Corner Table Drawn in AutoCAD


ready to be transferred for the CNC

Principle Six Applied


Sixth principle applied: Avoid separate Fasteners
Currently only one fastener used, with interlocking joints the self fastener used

Fastener used to prevent table top falling off


Product B depends on tightness of joints and friction to hold it together
Doesnt add any additional processes as it can have the holes drilled on the CNC
Advantages of using this principles:
1.

Ease of assembly on the consumer

2.

Product can be disassembled and reassembled a number of times

3.

Increased product flexibility

4.

No additional processes required to place the Knock Down fitting

5.

Fastener ensures the table top will remain in place

Avoid separate Fasteners

Separate Fasteners Used

Note: Due to the availability of the CNC, the production of


the DFM Table could not be produced. The use of this fitting
could not be seen in use.

Knock Down Fittings Altogether

Principle Seven Applied


Seventh principle applied: Minimise Assembly Directions & Methods
Product B is assembled in one direction Z-axis down

Removes any complexity or confusion in table assembly


Two pieces of equipment required for assembling Product B
Advantages of using this principles:
1.

Ease of assembly & disassembly

2.

Limited complexity in the assembly of Product B

3.

Self-assembled by the consumer

4.

Minimum assemble time required

5.

Product B can be assembled in one direction

Minimise Assembly Directions & Methods


Both Assembled from the ZAxis Down (Top-to-Bottom)

Principle Eight Applied


Eight principle applied: Maximise Compliance
Product B designed components designed to incorporate ease of assembly

Allows everyway to be the correct method of assembly


Removed any complexity or confusion in the assembly of Product B
Idiot proofed the assembly of the product
Advantages of using this principles:

1.

Increased the ease in the assembly of Product B

2.

Enabled any consumer to assemble and disassemble Product B

3.

Removed any complexity or confusion associated with the assembly of Product B

4.

No additional processes required to complete this

Maximise Compliance

Top Table Joiner

Bottom Table Joiner


Top & Bottom Joiner in Use through The DFM Table

Principle Nine Applied


Ninth principle applied: Minimise Handling
Designed to be flat packed product
Ease of storage and packaging
Advantages of using this principles:
1.

Product B can be sold flat packed

2.

Ease of storage and packaging

3.

Allowed for the incorporation of Product B to be abled to be disassembled

4.

Product Flexibility seen with the ease of storage

5.

Longer lead and set up time

Minimise Handling

DFM Corner Table Assembled & Dis-assembled

Conclusion of Product B
Evident significant consideration given to Design for Manufacture principles
Ease to manufacture and assemble with its current design

Allows for components to be used throughout other table variations


Ideal for mass manufacture with CNC being used to manufacture the product
CNC allows for high accurate precision and ease of repeatability of components
Relatively low lead, set up and manufacturing time associated with this product
Advantages of using Design for Manufacture in the design process:
1.

Reduction in lead, set up and manufacturing time

2.

Easier to manufacture and repeatability of product B

3.

Reduction in manufacturing cost, with increase in profits

4.

Product B Capable of mass production

Conclusion of Both Products

Picture References
http://www.amazon.co.uk/13mm-Threaded-Wood-Type-Insert/dp/B00EZ0FBT6
http://www.rockler.com/hardware/fasteners/knock-down-hardware
http://www.taiwantrade.com.tw/EP/fwangtzay/products-detail/en_US/473274/KnockDown_Bed_Hardware/