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Dfma I

The document discusses design for manufacturing and assembly (DFMA). It defines DFM and DFA as design approaches that minimize production costs and time to market while maintaining quality. The benefits of DFMA include reduced costs from fewer parts, increased reliability from simplified production, and improved quality. Effective DFMA requires a multi-disciplinary design team and applying guidelines such as minimizing part counts, using common parts, and designing for easy assembly.

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Johovani Suarez
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61 views22 pages

Dfma I

The document discusses design for manufacturing and assembly (DFMA). It defines DFM and DFA as design approaches that minimize production costs and time to market while maintaining quality. The benefits of DFMA include reduced costs from fewer parts, increased reliability from simplified production, and improved quality. Effective DFMA requires a multi-disciplinary design team and applying guidelines such as minimizing part counts, using common parts, and designing for easy assembly.

Uploaded by

Johovani Suarez
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Design for Manufacturing and Assembly I: General Principles

Manufacturing and Product Design San Jos State University

Design for Manufacturing and Assembly


Terminology: Design for (DFx) Design for Manufacturing (DFM) refers to design activity that is based on minimizing the cost of production and/or time to market for a product, while maintaining an appropriate level of quality. A primary strategy in DFM involves minimizing the number of parts in a product.

Design for Assembly (DFA) involves making directions and methods for attaching and joining the parts of a product simpler. DFMA refers to working both of these concepts together.
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Tech14x, Dr. Seth Bates

Benefits of DFM and DFA

Reduces part count, thereby reducing cost If a design is easier to produce and assemble, it can be done in less time, so it will be less expensive. Design for manufacturing and assembly should be used for that reason if no other. Increases reliability If the production process is simplified, there is less opportunity for errors. Generally increases the quality of the product for the same reason that it increases the reliability.

Tech14x, Dr. Seth Bates

DFM 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 guidelines with an understanding of explicit design goals. Make sure that the application of each guideline improves the design concept with respect to those goals
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Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines


Minimize part count by incorporating multiple functions into single parts. Several parts could be fabricated by using different manufacturing processes (sheet metal forming, injection molding). Ask yourself if a part function can be performed by a neighboring part.

Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines

Modularize multiple parts into single sub-assemblies.

Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines

Design to allow assembly in open spaces, not confined spaces. Do not bury important components.

Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines


Parts should easily indicate orientation for insertion. Parts should have self-locking features so that the precise alignment during assembly is not required. Or, Provide marks (indentation) to make orientation easier.

Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines


Use standardized products, and Standardize parts to reduce variety of operations, choices, and inventory burden.

Tech14x, Dr. Seth Bates

DFM and DFA Design Guidelines

Design parts so they do not tangle or stick to each other. Do

Dont

DO

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

Distinguish apparently similar parts


Distinguish different parts that are shaped similarly, or hard to distinguish, by non-geometric means, such as color coding.

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

Design parts to prevent nesting. Nesting is when parts that are stacked on top of one another clamp or stick to one another, for example, cups and coffee lids

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

Design parts with orienting features to make alignment easier.

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines


Provide

alignment features on the assembly so parts are easily oriented.

Do

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines


Design the mating parts for easy insertion or attachment. Provide allowance (tolerance) on each part to compensate for variation in part dimensions.

Case I

Case II

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

Design the first part large and wide for stability, then assemble smaller parts on top of it, sequentially.

Case I

Case II

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

If you cannot assemble parts from the top down exclusively, then minimize the number of insertion directions. Never require the assembly to be turned over.

Case I

Case II

Tech14x, Dr. Seth Bates

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DFM and DFA Design Guidelines

Joining Options: parts can be joined using fasteners (screws, nuts and bolts, rivets), snap fits, welds or adhesives. Design to eliminate fasteners and to place them away from obstructions

Tech14x, Dr. Seth Bates

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DFM and DFA Design Examples

Tech14x, Dr. Seth Bates

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Combining to Minimize the Number of Parts


To determine whether it is possible to combine neighboring parts, ask yourself the following questions:
Must the parts move relative to each other? Must the parts be electrically or thermally insulated? Must the parts be made of different material? Does combining the parts interfere with assembly of other parts? Will servicing be adversely affected?

If the answer to all questions is NO, you should find a way to combine the parts.

Tech14x, Dr. Seth Bates

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Minimizing the Number of Parts


Another Approach
The concept of the theoretical minimum number of parts was originally proposed by Boothroyd (1982). Generally, during the assembly of the product, a part is required only when;
1. 2. 3. A kinematic motion of the part is required. A different material is required. Assembly of other parts would otherwise be prevented.

If none of these statements are true, then the parts do not need to be separate entities and may be combined. Follow the KISS principal: KISS Keep It Simple Stupid
Tech14x, Dr. Seth Bates 21

End . . .
Design for Manufacturing and Assembly

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