Advanced Automotive

Systems
Course No: AE ZG514
BITS Pilani VS Gopal
Mechanical Engineering
Pilani Campus
 BITS Pilani
Pilani Campus

DFM/A
Design for Manufacturing and Assembly
Design for Manufacturing and Assembly

 Usually we encounter in our companies

• Cost reduction programs without compromising the quality of product
• Cost of the product ( manufacturing and assembly ) before or during concepts stage

 Most of the times highly experienced professionals involves in costing and estimating
process and assembly timings. It involves time and huge effort

Ex: Automotive sub assemblies such as engine and transmission, brake, steering, Seating
system with safety belt, air bag, Electronic devices, etc.,

 But companies can not afford to have such team because of time to market and
competition

BITS Pilani, Pilani Campus

Design for Manufacturing and Assembly

 Let us say if you are asked to take up the cost reduction program or
cost estimation( manufacturing and assembly)
• … what you will do?..... How do you start this activity.?

 There could be many situations – product concept stage, product

design stage, during product manufacturing , during product
benchmarking, and reverse engineering.

BITS Pilani, Pilani Campus

Design for Manufacturing and Assembly
DFA Product Implication
DFM concurrent costing

 “Manufacture” refers to the manufacturing of the individual component parts of a product or

fabrication assembly

 “Assemble” refers to the addition or joining of parts to form the completed product.

 Hence, DFM means the design for the (ease) of manufacture of parts and DFA means the design
of the product for the (ease) of assembly.

 Design for manufacture and assembly (DFMA) is a combination of DFA and DFM.

 DFMA is used for three main activities:

 As a guiding tool simplifying the product structure to reduce manufacturing and assembly
costs

 As a benchmarking tool to study competitors’ products and quantify manufacturing and

assembly difficulties

 As a should-cost tool to help control costs and to help negotiate suppliers contracts.
BITS Pilani, Pilani Campus
Design for Manufacturing and Assembly
DFA Product Implication
DFM concurrent costing

 DFM Concurrent Costing software provides an immediate, thorough understanding of the

primary cost drivers associated with manufacturing

 DFM guides you through an assessment of alternative processes and materials to help you
generate various design proposals.

 Cost results update automatically as you specify tolerances, surface finishes, and other part
details.

 Some benefits are

 A accurate cost-estimator :
o Provides accurate feedback on the change in cost associated with changes in parts or
their design.

o As changes in design takes paces the cost estimation can be done conveniently

o Dependence on historical pricing, supplier or high manufacturing experience is reduced

or somewhat removed
BITS Pilani, Pilani Campus
Design for Manufacturing and Assembly

 DFM software delivers ‘should-costing’ capability with access to the huge data base such
potential process, material, and machine combinations.

 One can easily create new operations and open and edit all of the existing libraries.

 DFM facilitate early-stage ‘costing’ to design, manufacturing, marketing, finance and purchasing
teams for better pricing and cost controls

 DFM analysis helps in identifying cost drivers of the proposed design. This leads to better design
trade off between useful function and cost.

 DFM tool can be used iteratively till enterprise choses the right design for further development

 DFM software facilitate an effective supplier-negotiations. The reports from DFM software will be
basis for negotiations ( for given process parameters and machine set up).

 DFM allows benchmark a competitor’s product and their product costing and thus enterprise
establishes the market feasibility for their products

BITS Pilani, Pilani Campus

Design for Manufacturing and Assembly

 DFM in complement with Design for Assembly (DFA) to find opportunities to reduce the
assembly time and cost

 DFA establishes a rating for product design in terms of its difficulty of assembly with help of
in built operations.

 DFA software facilitate decision in respect to field service and product maintenance plan

 The DFA index, a measure of assembly efficiency, serves as a basis for quantitatively
comparing design alternatives internally or against competing products.

 DFA facilitate design review in respect to assembly and cost of assembly

 DFM/A provides an opportunity for product innovation and improve design skills.

 The DFM/A software provides flexibility to engineers for cost effective and feasible design
solutions

BITS Pilani, Pilani Campus

Design for Manufacturing and Assembly

 Summary-Benefits of DFA Product Simplification Software

o Estimate difficulty of assembly

o Benchmarking existing products
o Add focus to the design reviews – design progress, verify improvements ( eliminating
redundant parts or operations & remove assembly difficulties)
o Of course sharpen design skills
o Integrate design and manufacturing

BITS Pilani, Pilani Campus

DFMA Analysis
Figure depicts the flow diagram of various steps undertaken in a DFMA study

Common steps taken in a DFMA study (Source: G. Boothroyd, P.

Dewhurst and W. Knight Product Design for Manufacture and
Assembly

BITS Pilani, Pilani Campus

Design for Manufacturing and Assembly

 Major Manufacturing Cost Models

 Assembly Fabrication, Automatic Assembly, Blow Molding, Die Casting, Plastic
Extrusion, Hot Forging, Injection Molding, Investment Casting, Machining,
PCBA, Sand Casting, Sheet Metal, Foam Molding, Thermoforming, etc.,

 Custom User Processes allows to incorporate costs and process time based on
your experience or based the company’s manufacturing database.

 Fully Populated Operations, Machine, and Material Libraries.

 Reports : Cost Breakdown, Cost vs. Life Volume Graphs.

 Manufacturing Profiles - Compare costs across different regions or suppliers.

 Integrated CAD Support

 Select features directly from the model
 STL, STEP, IGES Formats.
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DFMA Lab Evaluation

( practice files need to be uploaded in

1. DFMA Lab practice : 5 marks the concern folder. PDF documents
only allowed)
2. DFMA Lab quiz : 5 marks

3. DFMA Lab exam : 10 marks ( file and reports need to submitted)

BITS Pilani, Pilani Campus

DFMA

 Reduction in labour costs

 Reduction in part count
 Reduction in no. of separate Fasteners
 Reduction in the weight and thus cost
and other intangible benefits
 Reduction ins assembly Time
 Assembly cost
 Assembly tools
 Assembly operations
 Positive improvements in product
development cycle

BITS Pilani, Pilani Campus

DFMA

Tutorial
 Examples how one does without this software

 DFM
Microsoft Excel
Plastic 97-2003 Worksheet
manufacturing
component
cost sheet

Costing
sheet-brake assembly

 DFA

BITS Pilani, Pilani Campus

DFMA

Design Simplification

Part Cost or Total Costs of using the Parts?

 Material Cost
 Process Cost
 Tooling Cost
 Assembly Cost.

BITS Pilani, Pilani Campus

DFMA

Design Simplification Part Cost or Total Costs of using the Parts?

Guidelines Right Wrong

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DFMA

 DFA will not provide design solutions.

 DFA will only utilize a intuitive question-and answer interface that
which identifies opportunities for the cost reduction

BITS Pilani, Pilani Campus

DFMA

BITS Pilani, Pilani Campus

DFMA

Each part has a handling and insertion time penalty

 The more complex the part the larger the time penalty
 The more precise the alignment the heavier the penalty

BITS Pilani, Pilani Campus

DFMA

BITS Pilani, Pilani Campus

DFMA

DFMA - Speed Time to Market

Traditional process

DFMA process

 It is a claim. But individual has to validate their own projects and experience

BITS Pilani, Pilani Campus

DFMA

DFMA vs VAVE

 VA/VE - Systematic review of the value ( Functional modelling) of the

part/product and the evaluation of design alternatives that could produce
innovative product

 Emphasis is in identifying needed functions and eliminate unwanted functions

 Value is not synonym to cost

 If cost is main driver or objective then DFMA is compliment to this process

 DFMA - emphasis on the structure of the product and its simplification

 VAVE can be compliment to DFMA.

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DFMA

Summary

 Design determines more than 70% of product cost

 DFMA is a concurrent engineering(involves cross functional teams) to simplify

product structure in the early stages of design

 DFMA approach is to obtain an acceptable level of manufacturability, ease of

assembly, serviceability, product cost, product quality and time to market

 DFA software helps designers in estimating product assembly times and costs
based on reliable time standards

 DFM software contains process and material information and calculations for
estimating part manufacturing costs

BITS Pilani, Pilani Campus

DFMA

Tutorial
 Input to DFMA software 1. CAD drawing in neutral format
2. Drawings prints ( no CAD)
(Manual entry of part or assembly detail

 IGES (Initial Graphics Exchange Specification ), STL,STEP files provide

over all part dimensions, volume of the part

 Calculation of Surface area, perimeters, volumes: for drawing prints,

one has to calculate on paper or use one of DFMA’s tools ‘
‘Geometry Calculator’ using primitive shapes

 Out put of the DFMA software is report on cost & cycle timings,
comparisons between decisions taken( in chart format or table
format)
BITS Pilani, Pilani Campus
DFMA

Tutorial
 Prerequisite for using software for industry application is

 Awareness of the machining processes ( milling, drilling etc.,),

components manufacturing processes ( plastic, sheet metal, die
casting etc.,), jigs and fixture, Tool and Dies, assembly of
products, and typical costing(features) line items

 Exposure to PCB and PCBA and wire harness details

 Awareness of the product and its assemblies

BITS Pilani, Pilani Campus

DFMA

Tutorial

BITS Pilani, Pilani Campus

DFMA Lab Evaluation

1. DFMA Lab practice : 5 marks ( practice files need to beuploaded in

the concern folder)
2. DFMA Lab quiz : 5 marks

3. DFMA Lab exam : 10 marks ( file and reports need to submitted)

BITS Pilani, Pilani Campus

DFMA

Tutorial
 Assembly fabrication : Joining processes such as welding or
riveting to create a fabricated assembly.

 Cable harness assembly : The assembly of the harness can

be analysed using the operations contained in DFA’s
Operation Library,

 Deep Drawing : Sheet metal deep drawing exercise

 Die-casting : Costing of Die casting

BITS Pilani, Pilani Campus

DFMA

Tutorial

 Sheet metal : Analysis for sheet metal with turret press and
a compound die

 Pcb : The first step in the manufacture of the printed circuit

board assembly is the fabrication of the bare circuit board

 Machining full : Machining of components with holding

fixtures of work-piece

BITS Pilani, Pilani Campus

DFMA

Tutorial
 Machining quick : Full machining analysis and a Quick estimates
when detailed knowledge of machining operations for ball park
quotes

 Machining cell :A machining cell is normally a group of machines

where the parts output from the first machine in the cell feeds the
parts input to the second machine in the cell, whose parts output
feeds the third machine, and so on throughout the cell.

 Performing analysis : Analyse a small assembly in the DFA Product

Simplification software and then we redesign that assembly by
combining or eliminating parts to simplify the product structure.
The original and redesigned products are then compared using the
results features that are incorporated into the DFA software

BITS Pilani, Pilani Campus

DFMA

Tutorial
 Operation library : Any of your custom operation can be added to the library and then later
used in your analyses.

 Develop-User-Process : The User process program allows you to install into the DFM
Concurrent Costing software your own cost model for a manufacturing process.

BITS Pilani, Pilani Campus

DFMA Machining Full Analysis
Machining Quick Estimate
Machining Cell Analysis

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DFMA

BITS Pilani, Pilani Campus

DFMA DFA Analysis

BITS Pilani, Pilani Campus

DFMA DFM Die casting Analysis

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Input to DFMA software

Tutorial

BITS Pilani, Pilani Campus

Input to DFMA software

Tutorial

BITS Pilani, Pilani Campus

Input to DFMA software

Tutorial

BITS Pilani, Pilani Campus

Input to DFMA software

Tutorial

BITS Pilani, Pilani Campus

DFMA Book and dfma refereces
https://www.pdfdrive.com/product-design-for-manufacture-
and-assembly-third-edition-e175958126.html

https://www.dfma.com/software/dfma.asp

https://www.youtube.com/watch?v=_LlRof0K0OQ
Hot Chamber Die Casting & Cold Chamber Die Casting (3D animation)

https://www.youtube.com/watch?v=D6w6tZXKrls
Metal Mechanics 100 Ton Four Column (Post) Vertical Hydraulic Die Casting Trim Press

https://www.youtube.com/watch?v=bH1WlgGvOcE
( Part 1-Die Casting Process: What is the die casting process?)
https://www.youtube.com/watch?v=BoXD0ojw3UI
(Part 2 - Die Casting Defects: Where do they come from?)

https://www.youtube.com/watch?v=mMRdEfWoMPY
(Scrap Aluminium to pressure die casting Auto Components)

BITS Pilani, Pilani Campus