TAM302 Engineering Design Principles

Syllabus Topic:

Design for Manufacture & Assemble (DFMA) Introduction

Course Instructor:
Mike Philpott
Director of Concurrent Design & Manufacture Lab Associate Professor of Mechanical Science & Engineering

mphilpot@uiuc.edu
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Mfg. Alternatives: Investment/Cash Flow Decisions

x3 $75 $95 $55 $25 $0.30 $1.20 Trade off: Piece-part Recurring Costs versuscosts Non-Recurring Costs $10 $400 $8 $60,000 Example:$100 $60,000 tooling investment = $0.30 per part $5,000 $5 Tooling tooling investment = $95 per part costs
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Mfg. Alternatives: Investment/Cash Flow Decisions

x3 $95 $10 $75 $100 $55 $25 Piece-part costs $400 $8 Tooling costs $1.20 $5,000 $0.30 $60,000
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TAM 302 Design for Manufacture & Assembly

DFM: where M = Primary Mfg. Process

Select the Manufacturing Process Broad process knowledge Comparative cost knowledge

Improve the design for manufacturability

Analyze Cost

Do's & Don'ts (Rules/checklist) Cost-of-features knowledge

Quote Hist. data Models Software

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TAM 302 Design for Manufacture & Assembly

Design For Assembly (DFA) Assembly typically occupies between 40% and 60% of the total production period.
Select Assembly Method Manual Robotic Special purpose
Analyze for Assembly $ % Improve the design Combine Eliminate Simplify
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DFA principles BDI handbook Software (BDI, Sapphire, AEM)

TAM 302 Design for Manufacture & Assembly

DFA Example
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Assembly Labor Hours per Car

Japan U.S. (Big 3) Europe

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25
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Data Source: Detroit Free Press

DFA on Ford Taurus

Savings resulting from the use of DFA techniques on Ford's TAURUS Carline have been estimated to be > $1 billion.
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NCR 2760 Point-of-sale Terminal

Assembled blindfolded at DFA conf. in 1.5 mins. Reduced number of parts by 80% Reduced number of vendors by 65% Eliminated special assembly tools Estimated lifetime labor cost redn. of $1.1 million

Estimated savings from elimg. 1 screw $12,500

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Design For Assembly (DFA) Assembly typically occupies between 40% and 60% of the total production period.
Select Assembly Method Manual Robotic Special purpose
Analyze for Assembly $ % Improve the design Combine Eliminate Simplify
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DFA principles BDI handbook Software (BDI, Sapphire, AEM)

TAM 302 Design for Manufacture & Assembly

DFA Principles A. 'Product' Design for Assembly

The design of the entire product with a view to overall ease of assembly.

B. 'Component' Design for Assembly

The design of each component for ease of assembly to its neighbors.
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A. 'Product' DFA Principle #1.

1. Design for minimum number of parts

Is there a way that reduces the number of required parts? Are all components essential or can their functions be achieved by modifying an existing component? Can components be combined into one and manufactured as an integral multifunctional component?
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Ex. Application of Principle #1.

Old design= 8 parts New design= 3 parts

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Ex. Application of Principle #1.

Old Design = 25 parts New Design = 2 parts

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A. 'Product' DFA Principle #2. 2. Minimize number of fasteners and their components

Use snap fits where possible Use press fits where disassembly is not required Consider molded hinges, straps, or hook-unders Rationalize fasteners - types, lengths etc. Use one piece fasteners with lead in pilots Design geometry for automatic alignment
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Ex. Applications of Principle #2. Hook-under design to minimize number of fasteners

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Ex. Applications of Principle #2. Use single-piece fasteners, with guide pilots

or inserts

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Ex. Applications of Principle #2.

Recess for release of snap

Snap fits - can be designed for ease of assembly & disassembly

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Ex. Applications of Principle #2. Hinges, straps and/or snap fits:

Living hinges & straps Snap fits

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Ex. Applications of Principle #2. Rocker-box example: Good ergonomics / style

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A. 'Product' DFA Principle #3. 3. Design the product for assembly from one direction
Where possible assemblies should be designed so that a base piece is established, and remaining parts assembled from one, ideally vertical (Z) direction. It is difficult to feed components in from the side.

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A. 'Product' DFA Principle #4. 4. Avoid the need to turn the assembly over
If previously placed components have not been fastened, they may move out of position. Datum and location points change, and complicate the assembly process, which leads to jamming and assembly failure.

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A. 'Product' DFA Principle #5.

5. Standardize on Components, Materials, and Fasteners
Components can be difficult to differentiate, particularly small similar shaped ones. It is relatively common for feeders to become jammed because wrong parts have been fed in by operators. Considerable savings in storage, inventory, ordering etc.
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A. 'Product' DFA Principle #6.

6. Provide location surfaces that are closely related to datum surfaces

This ensures a known location tolerance for the automatic placing of components. Care should be taken to avoid tolerance buildup.

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A. 'Product' DFA Principle #7.

7. Consider ease of disassembly for maintenance, service, repair, and recycling
Integral snap fits, press fits, and retaining clips (circlips) allow compact designs, but if care is not taken, result in impossible disassembly Disassembly is frequently necessary due to incorrect assembly, the need to service/repair, and now the requirement to recycle
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A. 'Product' DFA Principle #8.

8. Adopt a modular design philosophy for the product group
Allows model variations to be accomplished at a sub-system level. Subassembly volumes increase, total parts decrease. Modular sub-assemblies may be built and tested by specialist teams (higher quality).

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Modular Design
Assembly time reduced from 540 hrs to 180 hrs

Design time per crane = 350 man hrs - 18hrs

Fabrication time = 1500 hrs to 550 hrs

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A. 'Product' DFA Principle #9.

9. Avoid the need for assembly adjustments
Eliminating adjustments will usually reduce assembly time considerably; and reduce service / maintenance Equipment going out of adjustment is one of the biggest causes of customer dissatisfaction. Spring loading can be used effectively to avoid assembly adjustment and to eliminate adjustment for wear.
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A. 'Product' DFA Principle #10.

10. Minimize assembly steps and extra operations
Each assembly step or operation must be resourced Mistakes in assembly are one of the greatest cause of product malfunction and customer returns. The fewer the steps the fewer the opportunities for error. Extra operations such as applying grease, sealants, turning part over etc. add to time and reduce assembly efficiency.
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B. 'Component' Design for Assembly The design of each component for ease of assembly to its neighbors;
i.e. the following tasks:

Feeding the components: from a bin, bulk feeder (e.g. bowl feeder), or magazine, or continuous strips. Orienting the components: by human operator, by the feeder tracks, and by the robot / workhead. Positioning and Placing the components
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TAM 302 Design for Manufacture & Assembly

B. 'Component' DFA Principle #1 1. Components should be symmetrical or have exaggerated assymetry

Symmetrical shapes have a predictable rest aspect Non-symmetrical shapes have an unpredictable resting aspect exaggerated assymetry and part falls on one of its flat faces
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B. 'Component' DFA Principle #2 2. Components should have the least number of important directions
To reduce the chance of correct feeding and positioning:

A
is better than

B
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is better than

B
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B. 'Component' DFA Principle #3

3. Provide Lead-in or Chamfers
Where possible make chamfers and lead-in angles generous, and avoid sharp corners, to avoid jamming:

OR

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B. 'Component' DFA Principle #4 & #5

4. Components should be free from burrs and flash, and be smooth in surface finish. 5. Design parts to prevent tangling:
Often a small design change can eliminate the tendency of components to tangle. Close ends and keep material thickness greater than gaps and slots:

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B. 'Component' DFA Principle #4 & #5 6. Consider the dimensions important to feeding and orienting
Loosely tolerancing non-functional dimensions can cause problems if the feeding and Feeder / Hopper orienting method is Delivery Tube not considered jamming may occur if components are at extremes of limit:
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