Workshop on

Design for Manufacturing

& Assembly
Conventions

Question?

Answer

Guideline

Anytime you can stop us

Length of Experience with DFMA

S.No. of Participant
Experience
Write on
White Board in Years
> 10
10
8
6
4
2
<2
Self Evaluation of Knowledge Level
in DFMA before Training
Knowledge &
Skill Level in Symbol Explanation
DFMA

1 Beginner
 Record of Self Evaluation Score on
White Board Before & After Program

Score
# Score After
Before
1
2
3
4
5
6
7
Objectives of 2 Day DFMA Training Program

1. Gain an overview of DFMA

2. Learn Guidelines for DFA
3. Calculate Design Efficiency of a given Assembly
4. Learn Guidelines for DFM of Sheet Metal Parts
Plastic Parts, Castings, Forgings,
Pressure Die Castings, Machining
5. Design For Serviceability
6. Design For Poka-Yoke (Meaning?)
7. Concurrent Costing
Manufacture =
1. Assemble
2. Construct
3. Create
4. Fabricate
5. Make
6. Make Up
7. Produce
DFM
= Design for Manufacturability
= Design to ease manufacture of parts that will
form product after assembly
Right or Wrong?

Manufacture

Assemble
 Manufacture =

•= Production of individual component parts of Product

•Examples:
•Castings
•Forgings
•Machining
•Molded Plastic Parts
•Sheet Metal Parts
•Pressure Die Castings …………
‘To assemble’

= “Addition / joining of parts to form completed product.”

DFA :

= Design for Assembly

= Design of product for ease of assembly

Sequence?

Manufacture Assembly

Assembly Function Vs Part Function?

? Assembly
?
Sub-Assembly

Component
Objectives of DFMA:

1. Simplifying Product Structure

2. Reduce Manufacturing & Assembly Costs
3. Quantify manufacturing & assembly difficulties
4. Estimate Tool costs to help negotiation with suppliers
5. Improve Product Quality
Introduction
To
DFMA
Analogy between Jungles of Africa
& Today’s Economy
Fortune 500 Ranking?
Answer this Question

“In future there will be only two types

of Organizations:
1&2”?

Tom Peters
Mantra of Japanese Product Success?
What do we see here?
What do we see here?
What do we see here?
What do we see here?
Mantra of Japanese Product Success?

D Q
C
Japanese Product Success; But How?

D Q
C
Japanese Product Success; But How?

DFMA
D Q
C
Acronym DFA = ?

DFA = ?
Acronym DFA = ?

Design For
Assembly

•Importance of DFA ?
•Term coined by?
•Aims at reducing part count in assembly, thus
improving the efficiency of design, making assembly
process easier & less time consuming
•Boothroyd & Dewhurst
Acronym DFA = ?

Design For
Assembly

•Aims of DFA?

•Part count in assembly

•η Assembly

•Make Assembly easier & less time consuming (Wheels?)

Acronym DFC = ?

DFC = ?
Acronym DFC = ?

Design For Cost

DFC = Design for Cost

Design Cost
‘Cost’ = ‘L.C Cost’?
Acronym DFD = ?

DFD = ?
Acronym DFD = ?

Design For
Detail

DFD = Design For Details

“God lives in Details ………………………”

“Assembly of Shaft & Bush”

Acronym DFE = ?

DFE = ?
Acronym DFE = ?

Design For
Environment

Meaning of “Environment”?

Assumes great relevance in view of global warming

DFE = ????
Acronym DFM = ?

DFM = ?
Acronym DFM = ?

Design For
Manufacturability

• DFM = Design For Manufacturability

• Coined By…….
• To improve design of components wrt
• Material
• Processabilty
• Achievable Accuracy
• Minimum Economic Quantity
• Cost
• Robustness
Acronym DFX = ?

DFX = ?
Acronym DFX = ?

Design For
Xcellence
Definition of Design For A to Z

A X = Σ (A to Z)
Z B C D
Y E
X
W F
V G
U DFX H
T I
S J
R K
Q L
P O N M
Definition of DFX

A C

M C

DFX
DFX

E D
Which is most important DFX = ?

DFX = ?
Which is most important DFX = ?

DFC = ?

DFC = ?
 PRIMA?
Process Information Map
How many Manufacturing & Assembly Processes …?
How many Manufacturing & Assembly Processes?
#1. Casting Processes
1.1 Sand casting
1.2 Shell molding
1.3 Gravity die casting
1.4 Pressure die casting
1.5 Centrifugal casting
1.6 Investment casting
1.7 Ceramic mold casting
1.8 Plaster mold casting
1.9 Squeeze casting
#2. Plastic & Composite Processing

2.1 Injection molding

2.2 Reaction injection molding
2.3 Compression molding
2.4 Transfer molding
2.5 Vacuum forming
2.6 Blow molding
2.7 Rotational molding
2.8 Contact molding
2.9 Continuous extrusion (plastics)
#3. Forming Processes
3.1 Forging
3.2 Rolling
3.3 Drawing
3.4 Cold forming
3.5 Cold heading
3.6 Swaging
3.7 Superplastic forming
3.8 Sheet-metal shearing
3.9 Sheet-metal forming
3.10 Spinning
3.11 Powder metallurgy
3.12 Continuous extrusion (metals)
#4. Machining Processes

4.1 Automatic and manual turning and boring

4.2 Milling
4.3 Planing & shaping
4.4 Drilling
4.5 Broaching
4.6 Reaming
4.7 Grinding
4.8 Honing
4.9 Lapping
#5. Non-traditional Machining Processes
5.1 Electrical Discharge Machining (EDM)
5.2 Electrochemical Machining (ECM)
5.3 Electron Beam Machining (EBM)
5.4 Laser Beam Machining (LBM)
5.5 Chemical Machining (CM)
5.6 Ultrasonic Machining (USM)
5.7 Abrasive Jet Machining (AJM)
#6. Assembly Processes

6.1 Manual assembly

6.2 Flexible assembly
6.3 Dedicated assembly
#7. Joining Processes

7.1 Tungsten Inert-Gas Welding (TIG)

7.2 Metal Inert-Gas Welding (MIG)
7.3 Manual Metal Arc Welding (MMA)
7.4 Submerged Arc Welding (SAW)
7.5 Electron Beam Welding (EBW)
7.6 Laser Beam Welding (LBW)
7.7 Plasma Arc Welding (PAW)
7.8 Resistance welding
7.9 Solid state welding
7.10 Thermit Welding (TW)
#7. Joining Processes

7.11 Gas Welding (GW)

7.12 Brazing
7.13 Soldering
7.14 Thermoplastic welding
7.15 Adhesive bonding
7.16 Mechanical fastening
Tightest Tolerance you are familiar with?
Color Symbols & their Meanings

Normal Working Capability of Process

Too Coarse a Tolerance for Process

Too Fine. Secondary Processes required

Tolerance Continuum
Too Fine Normal Too Coarse
Example?
 Process Capability Charts for
Compression Molding

0.05
Capability of Forging Process
Capabilities of Sheet Metal Processes
Process Capabilities of Drawing & Bending
Process Capabilities of Turning & Boring
Contents of New IMTMA Program

• Capabilities of Manufacturing Processes

• Costing of Designs based on Process & Volume
Application of Process Selection Example #1

Before Process Selection!

Any Suggestions?

After Process
Selection
Application of Process Selection
Example #2
Cars of the Future

more
Safer Lighter
Economical

more
Eco-friendlier Komfortable

To succeed in the market place, against

global competition
Front & Rear Crumple Zones
Instrument Panel of ETIOS Car Model
Instrument Panel Reinforcement Assembly with all its Child parts
Yield ratio increased from 55% to 75% !
Yield ratio increased from 55% to 75% !
Quality Acceptance Gauge
Creating Customer’s Delight

Particulars Initial Final Customer

Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded
Creating Customer’s Delight

Particulars Initial Final Customer

Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded

Number of
Press 15 10 Exceeded
Operations
Creating Customer’s Delight

Particulars Initial Final Customer

Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded

Number of Press
15 10 Exceeded
Operations
Method of Pressing &
Pressing Exceeded
Manufacture SPM
Creating Customer’s Delight

Particulars Initial Final Customer

Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded

Number of Press
15 10 Exceeded
Operations
Method of
Pressing Pressing & SPM Exceeded
Manufacture
Vide Toyota As per
Quality Inspection Acceptance Met
Standards Gauge
Particulars Initial Final Customer
Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded

Number of Press
15 10 Exceeded
Operations
Method of
Pressing Pressing & SPM Exceeded
Manufacture
Vide Toyota
As per Acceptance
Quality Inspection Met
Gauge
Standards

Within Within
Cost Met
Target Target
 Particulars Initial Final Customer
Customer Delivery by Expectations
Expectations NTTF
Yield Ratio 55% 75% Exceeded

Number of Press
15 10 Exceeded
Operations
Method of
Pressing Pressing & SPM Exceeded
Manufacture
Vide Toyota Inspection As per Acceptance
Quality Met
Standards Gauge

Cost Within Target Within Target Met

Delivery Time 5 months 5 months Met

 Weekly Magazine
Toyo Kaizai Dated 18.Dec. 2010

featuring a special
Article on Toyota Etios
Made in India
For Global Markets
ARTICLE: “CAN EFC SAVE TOYOTA?”
Toyota Production System
For IPRT

A View of Press Shop at

NTTF Industries manufacturing IPRT
Best Paper Award
 6 Ps of DFX in Plastic Parts

#1. Polymer

#6. Post-Consumer Life #2. Product

DFX
of
Plastic
Parts
#5. Profit
#3. Process

#4. Performance
#1 P = Polymer

• Molecule

• Properties
• Fillers
• Fibers
• Additives

• Compatibility
#2 P = Product

• Pellet

• Film / Fiber

• Component

• Assembly
#3 P = Process
• Molding
• Injection
• Extrusion
• Compression
• Heating & Cooling
• Pumping

• Morphology

• Forming

• Degradation
#4 P = Performance

• Thermal

• Mechanical

• Optical

• Environmental
#5 P = Profit

• Material Cost

• Mold Cost

• Machine & Energy Cost

• Labor & Automation Cost

Cost Breakup of Plastic Part
#6 P = Post Consumer Life

• Recycling

• Environment

• Sustainability

• Regulation & Legislation

#6 P = Post Consumer Life
#6 P = Post Consumer Life
Parallel Paradigms to DFMA………

DFMA

DFX Q
VA / VE / VM

Kano’s Model C
Process Selection

QFD
D
Robust Design
 Thank You
[email protected] 92
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
SOLIDIFICATION SOLIDIFICATION
PROCESSES PROCESSES

Sand Casting Sand Casting

Investment Casting Investment Casting
Die Casting Die Casting
Injection Molding Injection Molding
Structural Foam Molding Structural Foam Molding
Blow Molding (Ext.) Blow Molding (Ext.)
Blow Molding (Inj.) Blow Molding (Inj.)
Rotational Molding Rotational Molding

Normal Practice
Less Common
Not Applicable
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
SOLIDIFICATION SOLIDIFICATION
PROCESSES PROCESSES

Sand Casting Sand Casting

Investment Casting Investment Casting
Die Casting Die Casting
Injection Molding Injection Molding
Structural Foam Molding Structural Foam Molding
Blow Molding (Ext.) Blow Molding (Ext.)
Blow Molding (Inj.) Blow Molding (Inj.)
Rotational Molding Rotational Molding

Normal Practice
Less Common
Not Applicable
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
BULK BULK
DEFORMATION DEFORMATION
PROCESSES PROCESSES

Impact Extrusion Impact Extrusion

Cold Heading Cold Heading
Closed Die Forging Closed Die Forging
Powder Metal Part Powder Metal Part
Hot Extrusion Hot Extrusion
Roatary Swaging Roatary Swaging

Normal Practice
Less Common
Not Applicable
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
BULK BULK
DEFORMATION DEFORMATION
PROCESSES PROCESSES

Impact Extrusion Impact Extrusion

Cold Heading Cold Heading
Closed Die Forging Closed Die Forging
Powder Metal Part Powder Metal Part
Hot Extrusion Hot Extrusion
Roatary Swaging Roatary Swaging

Normal Practice
Less Common
Not Applicable
 EDM
ECM
Machining
REMOVAL
MATERIAL

PROCESSES
Cast Iron
Carbon Steel
Alloy Steel
Stainless Steel
Aluminium Alloys

Less Common
Not Applicable
Normal Practice Cu Alloys
Zinc Alloys
Magnesium Alloys
Titanium Alloys
Nickel Alloys
Refractory Materials
Thermoplastics
Thermosets
EDM
ECM
Machining
REMOVAL
MATERIAL

PROCESSES
 EDM
ECM
Machining
REMOVAL
MATERIAL

PROCESSES
Cast Iron
Carbon Steel
Alloy Steel
Stainless Steel
Aluminium Alloys

Less Common
Not Applicable
Normal Practice
Cu Alloys
Zinc Alloys
Magnesium Alloys
Titanium Alloys
Nickel Alloys
Refractory Materials
Thermoplastics
Thermosets
EDM
ECM
Machining
REMOVAL
MATERIAL

PROCESSES
 Wire EDM
Profiling
Cast Iron
Carbon Steel
Alloy Steel
Stainless Steel
Aluminium Alloys

Less Common
Not Applicable
Normal Practice
Cu Alloys
Zinc Alloys
Magnesium Alloys
Titanium Alloys
Nickel Alloys
Refractory Materials
Thermoplastics
Thermosets
Wire EDM
Profiling
 Wire EDM
Profiling
Cast Iron
Carbon Steel
Alloy Steel
Stainless Steel
Aluminium Alloys

Less Common
Not Applicable
Normal Practice
Cu Alloys
Zinc Alloys
Magnesium Alloys
Titanium Alloys
Nickel Alloys
Refractory Materials
Thermoplastics
Thermosets
Wire EDM
Profiling
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
Sheet-Forming Sheet-Forming
Processes Processes

Sheet Metal (Stamp/Bend) Sheet Metal (Stamp/Bend)

Thermoforming Thermoforming
Metal Spinning Metal Spinning

Normal Practice
Less Common
Not Applicable
 Refractory Materials
Magnesium Alloys
Aluminium Alloys

Thermoplastics
Titanium Alloys
Stainless Steel
Carbon Steel

Nickel Alloys

Thermosets
Zinc Alloys
Alloy Steel

Cu Alloys
Cast Iron
Sheet-Forming Processes Sheet-Forming Processes

Sheet Metal (Stamp/Bend) Sheet Metal (Stamp/Bend)

Thermoforming Thermoforming
Metal Spinning Metal Spinning

Normal Practice
Less Common
Not Applicable