Design for Assembly [ DFA ]

Introduction

The aim of design for assembly (DFA) is to simplify the product so that
the cost of assembly is reduced. However, consequences of applying
DFA usually include improved quality and reliability, and a reduction in
production equipment and part inventory. These secondary benefits
often outweigh the cost reductions in assembly.

DFA recognizes the need to analyse both the part design and the
whole product for any assembly problems early in the design process.
We may define DFA as "a process for improving product design for
easy and low -cost assembly, focusing on functionality and on
assemblability concurrently."

Basic DFA Guidelines

Here are some basic guidelines for DFA. Generally, you want to start
with a concept design and then go through each of these guidelines,
decide whether or not it is applicable, and the modify the concept to
satisfy the guideline. There is no guarantee that a given guideline will
apply to a particular design problem. Many of these guidelines are
similar or the same as

• Minimise part count by incorporating multiple functions into

single parts
• Modularise multiple parts into single subassemblies
• Assemble in open space, not in confined spaces; never bury
important components
• Make parts such that it is easy to identify how they should be
oriented for insertion
• Prefer self-locating parts
• Standardise to reduce part variety
• Maximise part symmetry
• Design in geometric or weight polar properties if nonsymmetrical
• Eliminate tingly parts
• Color code parts that are different but shaped similarly
• Prevent nesting of parts; prefer stacked assemblies
• Provide orienting features on no symmetries
• Design the mating features for easy insertion
• Provide alignment features
• Insert new parts into an assembly from above
• Eliminate re-orientation of both parts and assemblies
• Eliminate fasteners
• Place fasteners away from obstructions; design in fastener
access

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 • Deep channels should be sufficiently wide to provide access to
fastening tools; eliminate channels if possible
• Provide flats for uniform fastening and fastening ease
• Ensure sufficient space between fasteners and other features for
a fastening tool
• Prefer easily handled parts

Comparison of Assembly Methods

Figure 1: Relative costs of different assembly methods by type and

production volume.

Figure 2: Production ranges for each type of assembly method

Assembly methods can be divided into three major groups.

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In manual assembly, parts are transferred to workbenches where
workers manually assemble the product or components of a product.
Hand tools are generally used to aid the workers. Although this is the
most flexible and adaptable of assembly methods, there is usually an
upper limit to the production volume, and labour costs (including
benefits, cases of workers compensation due to injury, overhead for
maintaining a clean, healthy environment, etc.) are higher.

Fixed or hard automation is characterised by custom-built machinery

that assembles one and only one specific product. Obviously, this type
of machinery requires a large capital investment. As production
volume increases, the fraction of the capital investment compared to
the total manufacturing cost decreases. Indexing tables, parts feeders,
and automatic controls typify this inherently rigid assembly method.
Sometimes, this kind of assembly is called "Detroit-type" assembly.

Soft automation or robotic assembly incorporates the use of robotic

assembly systems. 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 or computer. Although this type of
assembly method can also have large capital costs, its flexibility often
helps offset the expense across many different products.

Graphically, the cost of different assembly methods can be displayed

as in Figure 1. The non-linear cost for robotic assembly reflects the
non-linear costs of robots (even small ones cost allot).

The appropriate ranges for each type of assembly method are shown
(approximately) in Figure 2.

Assembly methods should be chosen to prevent bottlenecks in the

process, as well as lower costs.

Design Guidelines for Manual Assembly

Obviously, the following guidelines depend on the skill of the worker:

• eliminate the need for workers to make decisions or

adjustments.
• ensure accessibility and visibility.
• eliminate the need for assembly tools and gauges (i.e. prefer
self-locating parts).
• minimise the number of different parts - use "standard" parts.
• minimise the number of parts.
• avoid or minimise part orientation during assembly (i.e. prefer
symmetrical parts).
• prefer easily handled parts that do not tangle or nest within one
another.

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Note that many products do not lend themselves to these guidelines.
Many such products are sold as "ready-to-assemble" kits or require
that assembly be shifted to cheaper labor markets.

Design Guidelines for Hard Automation

The main different here is that assembly is performed by machines

instead of by humans.

• reduce the number of different components by considering

1. does the part move relative to other parts?
2. must the part be isolated from other parts (electrical,
vibration, etc.)?
3. must the part be separate to allow assembly (cover plates,
etc.)?
• use self-aligning and self-locating features
• avoid screws/bolts
• use the largest and most rigid part as the assembly base and
fixture. Assembly should be performed in a layered, bottom-up
manner.
• use standard components and materials.
• avoid tangling or nesting parts.
• avoid flexible and fragile parts.
• avoid parts that require orientation.
• use parts that can be fed automatically.
• design parts with a low centre of gravity.

Sometimes it is too difficult to make parts symmetrical, often non-

functional features are added to a part to facilitate part feeding,
grasping, and orientation.

Design Guidelines for Soft Automation / Robotic Assembly

Compared to humans, robots are extremely inflexible and stupid.

However, they can be programmed to do one thing over and over
again with high speed and accuracy compared to humans.

• design the part so that it is compatible with the robot's end

effector.
• design the part so that it can be fed in the proper orientation.

Find below some examples

1. Ensure that parts most likely to require maintenance are easily

accessible.
2. Ensure that the degree of maintenance of your product is
consistent with your company's policy on making, stocking, and
supplying spare parts.
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3. Ensure tools needed for installation and maintenance are as
inexpensive and common as possible.
4. The decisions made in the first 15% of a product development
process fix 85% of the downstream quality and cost of the
product.
5. include all experts actively
6. resist making irreversible decisions
7. continually optimize the designed product and the design
process
8. prefer concepts that are easy to manufacture
9. prefer concepts that are easy to assemble
10. integrate design and manufacturing
11. do not over constrain or under constrain the design
12. look ahead of the current state of the design to forsee
problems
13. reduce the number of parts
14. increase interchangeability of parts; standardize parts;
minimize variation in parts
15. modularize functions and subassemblies
16. design multi-functional and multiple-use parts
17. avoid flexible components
18. avoid separate fasteners
19. improve robustness
20. allocate time/man-power based on cost/benefit analysis of
a proposed action
21. maximize yield of existing equipment
22. keep assemblies/components as independent as possible
23. maximize tolerances
24. test only what can be quantified; actively search for
testable aspects of a design
25. minimize machining set-ups and re-orientations
26. design parts for feeding and insertion into machines
27. perform functional analysis
28. tailor the manufacturing process to the character of the
product
29. study producibility and usability
30. design the fabrication process
31. design the assembly sequence for top-down assembly
32. minimize assembly instructions
33. use known/proven vendors and suppliers
34. use new technologies only when necessary
35. identify subassemblies as soon as possible in the design
process
36. do engineering changes in batches
37. integrate quality control with assembly
38. match assembly processes to tolerances
39. operate on a minimum inventory

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