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General Principles

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Design for Manufacturing and Assembly I: General PrinciplesDesign for Manufacturing and AssemblyBenefits of DFM and DFADFM and DFADFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design GuidelinesDFM and DFA Design Examples…Combining to Minimize the Number of PartsMinimizing the Number of Parts Another ApproachEnd . . .Design for Manufacturing Design for Manufacturing and Assembly I:and Assembly I:General PrinciplesGeneral PrinciplesManufacturing and Product DesignManufacturing and Product DesignSan JosSan JosééState UniversityState UniversityTech14x, Dr. Seth BatesTech14x, Dr. Seth Bates22Design for Manufacturing and Design for Manufacturing and AssemblyAssemblyTerminologyTerminology: Design for: Design for……((DFxDFx))¾¾Design for ManufacturingDesign for Manufacturing(DFM) refers to design (DFM) refers to design activity that is based on minimizing the cost of activity that is based on minimizing the cost of production and/or time to market for a product, production and/or time to market for a product, while maintaining an appropriate level of quality. A while maintaining an appropriate level of quality. A primary strategy in DFM involves minimizing the primary strategy in DFM involves minimizing the number of parts in a product.number of parts in a product.¾¾Design for AssemblyDesign for Assembly(DFA) involves making (DFA) involves making directions and methods for attaching and joining directions and methods for attaching and joining the parts of a product simpler.the parts of a product simpler.¾¾DFMADFMArefers to working both of these concepts refers to working both of these concepts together.together.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates33Benefits of DFM and DFABenefits of DFM and DFA¾¾Reduces part count, thereby reducing costReduces part count, thereby reducing cost……If a design is easier to produce and assemble, it If a design is easier to produce and assemble, it can be done in less time, so it will be less can be done in less time, so it will be less expensive. Design for manufacturing and assembly expensive. Design for manufacturing and assembly should be used for that reason if no other.should be used for that reason if no other.¾¾Increases reliabilityIncreases reliability……If the production process is simplified, there is less If the production process is simplified, there is less opportunity for errors.opportunity for errors.¾¾Generally increases the quality of the productGenerally increases the quality of the product……for the same reason that it increases the reliability.for the same reason that it increases the reliability.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates44DFM and DFADFM and DFA• DFM and DFA start with the formation of a design team which must be multi-disciplinary, including:engineers, manufacturing managers, cost accountants, and marketing and sales professionals.• The most basic / simplest approach to Design for Manufacturing and Assembly is to apply a set of design guidelines.• You should use design guidelineswith an understanding of explicit design goals. Make sure that the application of each guideline improves the design concept with respect to those goalsTech14x, Dr. Seth BatesTech14x, Dr. Seth Bates55DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Minimize part countMinimize part countby incorporating multiple functions into by incorporating multiple functions into single parts. single parts. ¾¾Several parts could be fabricated by using different Several parts could be fabricated by using different manufacturing processes (sheet metal forming, injection manufacturing processes (sheet metal forming, injection molding). molding). ¾¾Ask yourself if a part function can be performed by a Ask yourself if a part function can be performed by a neighboring part.neighboring part.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates66DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾ModularizeModularizemultiple parts into single submultiple parts into single sub--assemblies.assemblies.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates77DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Design to Design to allow assembly in open spacesallow assembly in open spaces, not , not confined spaces. Do not bury important components.confined spaces. Do not bury important components.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates88DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Parts should easily indicate orientation for insertionParts should easily indicate orientation for insertion. . ¾¾Parts should have selfParts should have self--locking features so that the precise locking features so that the precise alignment during assembly is not required. Or, alignment during assembly is not required. Or, ¾¾Provide marks (indentation) to make orientation easier. Provide marks (indentation) to make orientation easier.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates99DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Use standardized products, andUse standardized products, and¾¾Standardize parts to reduce variety of Standardize parts to reduce variety of operations, choices, and inventory burden.operations, choices, and inventory burden.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates1010DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Design parts so they do not tangle or stickDesign parts so they do not tangle or stickto each to each other.other.Don’tDoDOTech14x, Dr. Seth BatesTech14x, Dr. Seth Bates1111DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Distinguish Distinguish ‘‘apparently similarapparently similar’’partsparts¾¾Distinguish different parts that are shaped similarly, or hard tDistinguish different parts that are shaped similarly, or hard to o distinguish, by nondistinguish, by non--geometric means, such as color coding.geometric means, such as color coding.Tech14x, Dr. Seth BatesTech14x, Dr. Seth Bates1212DFM and DFA Design GuidelinesDFM and DFA Design Guidelines¾¾Design parts to prevent nestingDesign parts to prevent nesting. . Nesting is when parts that are stacked on top of


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