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DFA (Design For Assembly) : - Definition and Purpose

The document discusses Design for Assembly (DFA) which aims to minimize assembly cost by optimizing the assembly process and reducing part count. It does this by examining assembly steps, part handling requirements, part relevance, and theoretical minimum number of parts. The purpose of DFA is to make assembly easier by designing parts that are easy to insert and handle, self-aligning, minimize adjustments, and reduce unnecessary fasteners. DFA analysis helps optimize the assembly process and reduce costs.

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Chethan Sk
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54 views

DFA (Design For Assembly) : - Definition and Purpose

The document discusses Design for Assembly (DFA) which aims to minimize assembly cost by optimizing the assembly process and reducing part count. It does this by examining assembly steps, part handling requirements, part relevance, and theoretical minimum number of parts. The purpose of DFA is to make assembly easier by designing parts that are easy to insert and handle, self-aligning, minimize adjustments, and reduce unnecessary fasteners. DFA analysis helps optimize the assembly process and reduce costs.

Uploaded by

Chethan Sk
Copyright
© © All Rights Reserved
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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DFA

(Design for Assembly)


Definition and Purpose
Design for Assembly is a method of analyzing components
and sub-assemblies in order to:
Optimize the assembly process steps
Identify part relevance
Estimate the cost of assembly

The purpose of DFA is to minimize assembly cost by


optimizing the assembly process and reducing the number
of parts.

DFA Process
Prior to examining a system for DFA you need
a model, drawing or prototype of the assembly
a proposed assembly sequence.

Examine Assembly Steps


Part handling
Part insertion/orientation
Non-value added process steps

Examine Part Relevance


Minimize part count
Determine theoretical minimum number of
parts
Minimize the levels of assembly

Part Handling
Design parts that are easy
to handle
Alpha/Beta angle symmetry
Alpha: axis perpendicular to
direction of insertion
Beta: axis in direction of
insertion

Part Handling
Geometric Size
Design parts that are ideal in terms of size
Large parts
Require two hands
Require mechanical assistance

Tiny parts
Require tweezers
Require magnification

Part Handling
If possible, minimize
Flexible parts (wiring, tubing, gaskets)
difficult handling

Parts that tangle


Slippery or sticky parts
(pre-lubricated, pre-adhesive)

Parts with sharp edges or points

Part Insertion
Design for uni-directional assembly,
preferably using gravity
Assembly to a stable base

Part Insertion
Design parts that are easy to align and position,
design parts that self-fixture.

Part Insertion
Consider access and visibility for ease of insertion.

Part Insertion
Design parts that self align

Mistake Proofing Issues (Poka-Yoke)


Cannot assemble wrong
part
Cannot omit part
Cannot assemble part
wrong way around.
symmetrical parts

asymmetrical parts

Part Insertion
Avoid the need for adjustments and
reorientations during assembly
Use unidirectional assembly where
possible

Minimize Part Count


Design for the minimum number of without sacrificing
quality.
Fewer parts mean
a faster and more accurate assembly process
it results in:
Reduced inventory and number of vendors
Reduced assembly time and savings in material costs
Simplified assembly processes

It can be accomplished by:

Minimizing numbers and types of fasteners, cables, etc.


Encouraging modular, interchangeable assemblies
Building in self-fastening features
Minimizing the number of levels of assembly

Eliminating Parts
Avoid separate fasteners: design the fastening functions into the
parts.

Eliminating Fasteners

Fastener Cost
Select the most

inexpensive
fastening
method
required

screwing

riveting

plastic bending
snap fit

Self-Fastening Features

Theoretical Number of Parts


1) Is the component/sub-assembly used only for fastening or securing
other items? If yes, try to eliminate.
2) Is the component/sub-assembly used only for connecting other items
(for example, wiring harnesses, belts, chains)? If yes, try to eliminate.
3) During operation, does the component move relative to all other parts
already assembled? If no, skip question #4
4) Must the part be made of a different material than, or isolated from all
other parts already assembled? Only fundamental reasons concerned
with material properties are acceptable. If no, go to question #5
5) Must the part be separate from all other parts already assembled
because of any necessary assembly or disassembly of the other parts
would otherwise be impossible? If no to questions #3-5, part is
theoretically unnecessary.
6) If this is a part in a sub-assembly, can any part be combined with
another part in the parent assembly?

Three solutions to the same design issue.

Comments?
Which do you prefer?
Why?

DFA Software
Will allow user to see the effects of part
handling decisions.
Will help user to work toward minimizing part
count.

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