Module Title Module Code

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Module Information Design for Manufacturing and Assembly PDN505

MODULE SUMMARY

Aims and Summary This module is intended to prepare students to design for manufacturing and assembly by applying DFMA principles. Students will be taught DFMA techniques to simplify product structure, reduce assembly time and process, improve serviceability, reduce cost and time to market. Principles of design for assembly and design for environment will be discussed. Students will use Boothroyd and Dewhurst DFMA software to evaluate designs. Module Size and Credits Module size CATS points ECTS credits Open / restricted Availability on/off campus Total student study hours Number of weeks Centre responsible Academic Year Single 12 N/A Restricted On Campus/Off campus 120 4 weeks Full-time or 8 weeks Part-time. Product Design Centre / Department of Mechanical and Automotive Engineering 2009

Entry Requirements (pre-requisites and co-requisites) Normally to be qualified for entry to the Postgraduate Engineering Programme Excluded Combinations None Composition of Module Mark (including weighting of components) Full-time / Part-time : 50% Written Examination and 50 % Assignment Pass Requirements A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment and overall 40% marks are required for a pass Special Features 80% attendance in theory and 80% attendance in laboratory are required. It is likely that considerable time will be spent in School facilities outside of normal timetabled class time. Courses for which this module is mandatory M.Sc. [Engg] in Product Design Courses for which this module is a core option None

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TEACHING, LEARNING AND ASSESSMENT After undergoing this module, students will be able to: 1. Analyse materials, manufacturing process and assembly 2. Apply DFMA guidelines for manufacturing and assembly 3. Design products for environment and serviceability 4. Use Boothroyd and Dewhurst DFMA software to evaluate designs

Intended Module Learning Outcomes

Indicative Content Class Room Lectures 1. DFMA overview - What is DFMA, Design and product cost, Phases of innovation, DFMA product development process, DFMA software, DFMA support areas, Concurrent costing, Benefits of DFMA, Case studies General design principles for manufacturability - Simplicity of design, Standard materials and components, Standardised product design, Liberal tolerances, Use of the most processable materials, Teamwork across the organisation, Avoidance of secondary operations, Design for the expected quantities, Taking care of process requirements, Use of appropriate PDM and PLM software tools. Selection of materials and manufacturing processes - Classification of manufacturing processes and the materials that can be worked by each of these processes. The capability of different manufacturing processes to produce part attributes for DFM and assembly attributes for DFA. DFMA roadmap - Role and importance of DFMA in product design, Design architecture, Theoretical minimum number of parts, Assembly efficiency, Assembly systems, Choice of assembly method, DFMA goals, DFMA drawbacks, Concurrent engineering process. Design for assembly-Guidelines - Principles of reducing parts, Simple design alternatives, Part count reduction criteria, Specific guidelines for design for assembly with examples. DFMA methodologies - Need for DFMA methodologies, DFMA methodologies available, Hitachi, Boothroyd-Dewhurst DFMA, Lucas/Hull DFA, Design Rules, DFMA examples Design for manual assembly - Modular design, Standardisation, Effect of parts on handling time, DFA guidelines, Choice of assembly method, Design guidelines for manual assembly, Design guidelines for insertion and fastening. Design for automatic assembly - Operations involved-storing, Handling, Positioning and adjusting , Guidelines for ease of assembly-arranging, Standardising and simplifying assembly operations with examples Dimensions, fits and tolerances for assembly - Variations in dimensions, Geometric properties and surface finish during production, Need for interchangeable manufacture, Fits and tolerances, Dimensional tolerances obtained from manufacturing processes, geometric tolerances and surface finish obtainable from manufacturing processes, Gauging for production. Design for sheet metal parts - Conventional stamping processes, Design recommendations for sheet metal parts, Material utilisation, Strip layout, Reinforcing ribs, Screw threads, Extrude Screw, Screw threads, DFM for formed parts, DFM for drawn parts, Tolerances on sheet metal parts. Design for injection moulding - Thermoplastic materials, Injection moulding process, Typical characteristics of injection moulded parts, Effects of shrinkage, Economic production quantities, Design recommendations on gating, Ejector pin locations, Wall thickness, Holes, Ribs, Bosses, Sliding cores, Undercuts, Threads, Inserts, Drafts, Radii, Surface finish, Parting lines, Tolerances on moulded parts Design for die casting - Effectiveness of die castings, Metal flow, Uniform wall thickness, Ribs, Intersection of ribs, Bosses, Drafts, Side cores, Case threads, Inserts, Machining allowance, Design for flash and gate removal, Runners, Ejector pins, Tolerances on die cast parts. Design for serviceability - Increase product reliability, Simplify design, Fewer parts, Standard and interchangeable replacement parts, Design and process FMEA, Simplify service procedure, Easy access to all test, Adjustment and service points, Easy disassembly. Design for environment - Stages of a product life cycle, Design for environment, Benefits of eco design, External and internal drivers for eco design, Local laws and certifications, environment driven innovation, Design considerations for product use, End of life, Materials, manufacturing, Disassembly, Recycling, Fastening guidelines, Environmental standards. Best practices for manufacturing processes - Sources of defects, Elimination of defects, Avoiding human errors, Five elements of production, Poka yoke in design and manufacture with

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examples Laboratory Practice 1. Reverse engineering of product to study DFMA principles. 2. Use of Boothroyd and Dewhwrst Software to estimate design efficiency and cost Teaching and Learning Methods 1. Theoretical Knowledge [~30% of module time] a. Face to face lectures from a module leader - 30 hours b. Case study teaching and group discussion - 6 hours 36 hours 2. Laboratory Practice (Skills) [~ 25% of module time] 30 hours 3. Application Orientation and Problem Solving [45% of module time] a. Reading b. Research c. Written Examination d. Assignment Solving and Documentation 54 hours Method of Assessment Part-A Written Examination [50% Weightage] At the end of the module, normally on the last day of the last week of the module, written examination is conducted to test students understanding of taught theoretical concepts. The question paper will comprise either or a combination of the following: 6 questions, out of which 5 questions need to be answered Practical laboratory work Presentations Field work Creation of a physical model

The marks scored by the student will be scale down to 50% weight. Part B Assignment [50% Weightage] Students are required to submit word processed assignment report on formally announced last day of the module. Assignment tests students problem solving skills based on taught concepts. The assignment is assessed for 100 marks but scored marks is scaled down to 50% Assessment Learning Outcomes Part A Part B 1 X X 2 X X 3 X X X 4

Both written examination scripts and assignment reports will be double marked/valued Re-assessment

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A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment are required for a pass in the module. A student failing in any one of the components or both is considered as FAIL in the module. A failed student is required to retake the module at the next opportunity. A maximum of 3 attempts including the original are allowed. Date of Last Amendment May 2009 3. MODULE RESOURCES

Essential Reading 1. Module Notes

Recommended Reading Books 1. 2. 3. Geoffrey Boothroyd, et al, Product Design for Manufacture & Assembly, Revised & Expanded, 1996 James B Bralla, Design for Manufacturability Hand Book, McGraw Hill, 1986 John W.Priest, Jose Sanchez, Product Development and Design for Manufacturing, Marcell Decker, 2001

Journals 1. Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture Published by Professional Engineering Publishing. 2. CIRP Annals - Manufacturing Technology Published by International Academy for Production Engineering Magazines None Internet Sites 1. www.dfma.com/software

Laboratory Hardware: Computers and Workshop facility Software: Boothroyd and Dewhwrst DFMA Software Software Manual: Boothroyd and Dewhwrst DFMA Software manual

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MODULE ORGANISATION

Module Leader Name Room Telephone number E-mail Prof. M.N. Sudhindra Kumar G-13 080-2360 5539- 112 sudhindra@msrsas.org

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Date and Time of Examination As per time table

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Subject Quality and Approval Information Subject Quality Group / Subject Board Subject Assessment Board Shortened title Date of approval by MARP Mechanical and Automotive Engineering Postgraduate Engineering Programmes DFMA May 2009

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