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Design and Analysis of Grass Cutting Machine By Using DFMA Method

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Design and Analysis of Grass Cutting Machine By Using

DFMA Method

Nur Syaiyidah Mohamad Salikan1, M F Rosli 1,2

, Nor Nasyitah Mohammad1,
Irfan Abd Rahim1,2 and M K Fadzly2,3
1
School of Manufacturing Engineering,Universiti Malaysia Perlis (UniMAP), Kampus
Tetap Ulu Pauh, Jalan Arau-Changlun, 02600 Arau, Perlis, Malaysia.
2
Green Design and Manufacture Research Group, Center of Excellence Geopolymer
and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, 01000 Kangar,
Perlis, Malaysia.
3
Centre of Diploma Studies (CDS), Universiti Malaysia Perlis (UniMAP), S2-L1-26,
Kampus UniCITI Alam Sg. Chuchuh, 02100 Padang Besar (U), Perlis, Malaysia

Email: [email protected]

Abstract. This paper describes about the implementation of redesign the component of grass
cutting machine by using the application of Design for Manufacturing and Assembly (DFMA)
methodology. The scope based on the existing grass cutting machine and the appropriate of
DFMA methodology. The data was analysed by using Boothroyd-Dewhurst Design for
Manufacture and Assembly method to verify the design efficiency, handling ratio and fitting
ratio to achieve. The new proposed design of grass cutting machine drawn using CATIA V5
software based As a result, the assembly time for redesign showed an improvement of 18.68%
where the assembly time was reduced from 568.84 s to 462.59 s and design efficiency was
increased 8.33% from 24.40% to 34.70%. The total part, handling ratio fitting ratio and cost of
existing design is reduced. Eventually, the improvement of redesign grass cutting machine the
best design with optimal value is accomplished.

1. Introduction
Design for manufacture and assembly (DFMA) is a combination of design for assembly (DFA) and
design for manufacture (DFM). The term DFMA is defined as a set of guidelines developed to ensure
that a product is designed so that it can be easily and efficiently manufactured and assembled with a
minimum laborious effort, assemble time, and cost to manufacture the product [1-4]. DFA is
considering and resolving the possible problems in the assembly process at the early stage of the
design which can make sure the part will be assembled with high speed, low cost and productivity [5].
DFM is that by considering the limitations related to the manufacturing at the early stage of the design
which is the design engineer can make selection among the different materials, different technologies
and estimate the manufacturing time [6,19]. The quality of new product was increased with the good
development period including design, technology, manufacturing, service and so on [7-9].
Simultanously, the cost also decrease, including the cost of design, technology, manufacturing,
delivery and technical support. The short developing cycle time, including the time of design,
manufacturing preparing, and repeatedly calculation [10-11].

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

2. Research Objective

The main objective of this research is to analyse design efficiency on current design and redesign of
grass cutting machine by using DFMA method. By using the DFMA as the benchmark tool was used
to increase the design efficiency and minimize the quantity of part in manufacturing and assembly
costing [2-4,20,21].

3. Design For Manufacture and Assembly (DFMA) of Grass Cutting Machine

Figure 1. Boothroyd-Dewhurst DFMA Methodology.

3.1. CAD Drawing

CAD design is capable of producing the designer with extremely precise designs and prospects. CAD
drawing also helps the designer in evaluating the design and redesigning the drawing. Figure 1 shows
the first process in Boothroyd-Dewhurst DFMA method is to design the concept [12]. Figure 2 shown
the features of current grass cutting machine by using CAD drawing.
.

Figure 2. CAD Modelling of Grass Cutting Machine.

3.2. Design For Assembly (DFA)

Design for Assembly (DFA) is an approach to reduce the cost of the product and time of assembly by
simplifying the product and process. There are two uses of DFA. It may use to redesign a product
already in manufacture or product being remarketed or reversed engineering. Beside that DFA may
also use for analysis of a product while it is in design [13,14, 18, 22]. The DFA method should be
considered at all stages of the design process especially in the early stages [15, 23-25]. In this paper,
type of assembly that must be considered is manual assembly by. The manual assembly can be
measure by using DFA tool, which is the handling and insertion time table.
Table 1 shows the current quantity parts used, handling time, insertion time, theoretical part count
and assembly time for each part for current grass cutting machine. The parts should be consider the
orientation of the part rotating (Alpha –  and Beta - ) from X and Y-axis. While handling time and
insertion time are selected based on the table estimate time For Manual Handling Time and Manual
Insertion Time. The theoretical part count states the important of the part for grass cutting machine. If
the part is important to the main function of the grass cutting machine, the value of theoretical part
count is 1 and the less important part to the function of the grass cutting machine which is that parts
can be eliminated or redesign is 0 [15].

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Table 1. Existing Part Assembly Time.

Theoretical
Part Count

Assembly
Handling

Insertion

Time (s)
Quantity

Time (s)

Time (s)

Total
 (°)

 (°)
No Part Name

1 Bolt M10 X 25 1 0 360 0 1.5 3.5 5

2 Washer 1 0 180 0 1.88 2.5 4.38
Bolt Protection 1 1 360 0
3 1.5 1.5 3
Cover
4 Cutter Holder Cap 1 1 360 0 1.5 1.5 3
5 Cutter Holder 1 1 360 0 1.5 1.5 3
6 Gear Case 1 1 360 360 3 6 9
7 Bolt M6 X 12 2 0 360 0 3 7 10
8 Screw M5 X 20 3 0 360 0 4.5 10.5 15
9 Aluminium Pipe 1 1 180 0 1.5 5.5 7
10 Shaft Drive 1 1 180 90 1.13 5.5 6.63
11 Bushing 1 1 360 0 1.5 2.5 4
12 Flexible Inner 1 1 180 0 2 5.5 7.5
13 Flexible Shaft 1 1 180 0 1.13 5.5 6.63
14 Bolt M6 X 25 2 0 360 0 3 7 10
15 Safety Guard Bracket 1 1 360 360 1.95 6 7.95
16 Safety Guard 1 1 360 360 1.95 5 6.95
17 Handle 1 1 360 360 1.95 4 5.95
18 Handle Bracket 1 0 360 360 1.95 6 7.95
19 Bolt M6 X 45 2 0 360 0 3 7 10
20 Grip 1 1 360 360 3 5 8
21 Joint Pipe 1 1 360 360 2.73 5 7.73
22 Screw M5 X 10 1 0 360 0 1.5 3.5 5
23 Screw M5 X 25 1 0 360 0 1.5 3.5 5
24 Stop Button 1 1 360 0 1.5 2.5 4
25 Stop Button Bracket 1 1 360 0 1.5 1.5 3
26 Throttle Lever 1 1 360 360 1.95 6 7.95
27 Bolt M5 X 25 1 0 360 0 1.5 3.5 5
28 Blade 1 1 360 180 1.8 6 7.8
29 Shoulder Frame 1 1 360 360 1.95 0 1.95
30 Lifting Metal 1 1 360 360 1.95 4.5 6.45
Shoulder Plate
31 1 1 360 360 1.95 6 7.95
Holder A
Shoulder Plate
32 1 1 360 360 1.95 6 7.95
Holder B
33 Screw M5 X 12 8 0 360 0 12 28 40
34 Shoulder Plate 1 1 360 360 3 6 9
35 Bolt M6 X 16 3 0 360 0 4.5 10.5 15
36 Shoulder Belt 1 1 360 360 1.95 2.5 4.45

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Table 1. Existing Part Assembly Time (Continued…).

Theoretical
Part Count

Assembly
Handling

Insertion
Quantity

Time (s)

Time (s)

Time (s)
Total
 (°)

 (°)
No. Part Name

37 Engine Base A 1 1 360 360 1.95 6 7.95

38 Engine Base B 1 1 360 360 1.95 6 7.95
39 Cushion Rubber 4 1 180 0 6 10 16
40 Rotating Shaft 1 1 180 0 1.5 2.5 4
41 Bearing 1 1 180 0 1.5 5 6.5
42 Nut M10 2 0 360 0 3 7 10
43 Screw M6 X 12 3 0 360 0 4.5 10.5 15
44 Fuel Tank 1 1 360 360 3.9 13.5 6.45
45 Lid Tank 1 1 360 0 1.5 1.5 3
46 Fuel Tank Band 2 1 360 360 3.9 12 15.9
47 Screw M5 X 20 2 0 360 0 3 7 10
Fuel Pipe Protection
48 1 1 180 0 1.5 2.5 4
Coil
49 Fuel Pipe 1 1 180 0 1.5 2.5 4
50 Fuel Pipe Clip 2 1 180 0 3 5 8
51 Tank Holder Metal 1 1 360 360 1.95 6 7.95
52 Engine Cover 1 1 360 360 1.95 5 6.95
53 Screw M4 X 12 1 0 360 0 1.5 3.5 5
54 Screw M4 X 10 2 0 360 0 3 7 10
55 Rope 1 1 180 0 1.88 2.5 4.38
56 Recoil Starter Body 1 1 360 360 1.95 6 7.95
57 Starter Handle 1 1 360 0 1.5 1.5 3
58 Starter Rope Reel 1 1 180 0 1.88 5 6.88
59 Screw M5 X 12 1 0 360 0 1.5 3.5 5
60 Cleaner Body 1 1 360 360 1.95 6 7.95
61 Cleaner Fixing Base 1 1 360 180 1.5 2.5 4
62 Cleaner Element 1 1 360 180 1.5 2.5 4
63 Screw M4 X 25 2 0 360 0 3 7 10
64 Clutch Case 1 1 360 360 1.95 2.5 4.45
65 Locking Pin 1 0 360 0 1.5 1.5 3
66 Fan Case 1 1 360 360 2.73 6 8.73
67 Screw M5 X 20 6 0 360 0 9 21 30
68 Muffler 1 1 360 360 1.95 6 7.95
69 Screw M6 X 65 2 0 360 0 3 7 10
70 Plug Cap 1 1 360 360 2.73 4 6.73
71 Stop Wire 1 1 180 0 1.5 2.5 4
72 Engine 1 1 360 360 5 8 13
Total parts 72 50 Total Assembly Time 568.84

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

3.3. Design Efficiency

The important data in the DFA method is the used the "Efficiency of assembly" of the proposed
design. Basically, there have two major factors affecting cost of product assemblies or subassembly
are:
i) Parts number.
ii) The easy of manual insertion, handling and fastening.

 
  

 3 
  (1)

   


   

"#
! = x 3s
"$%.%&

! = 0.264 @ 26.4%

Based on the calculation above, the current design efficiency of grass cutting machine is 26.4%.
Therefore, the redesign efficiency of grass cutting machine must be higher than the current design
efficiency.

3.4. Design for Manufacturing (DFM)

Design for Manufacturing (DFM) is to make easier for manufacturing and concerned with reducing
overall part production cost by minimizes complexity of manufacturing operations [16-18]. The DFM
will be analysing the material and process used to ease the design for grass cutting machine. Table 2
shows the Manufacturing Process and Material used for Each Part of grass cutting machine.
Table 2. Manufacturing Process And Material Used of Grass Cutting Machine.

No. Part Name Material Process

1. Bolt M10 X 25 Carbon Steel Machining
2. Washer Carbon Steel Sheet Metal Stamping
3. Bolt Protection Cover Carbon Steel Sheet Metal Stamping
4. Cutter Holder Cap Carbon Steel Die Casting
5. Cutter Holder Carbon Steel Die Casting
6. Gear Case Carbon Steel Die Casting
7. Bolt M6 X 12 Carbon Steel Machining
8. Screw M5 X 20 Carbon Steel Machining
9. Aluminium Pipe Aluminium Hot Extrusion
10. Shaft Drive Carbon Steel Hot Extrusion
11. Bushing Carbon Steel Die Casting
12. Flexible Liner Rubber Injection Molding
13. Flexible Shaft Carbon Steel Die Casting
14. Bolt M6 X 25 Carbon Steel Machining
15. Safety Guard Bracket Abs Injection Molding

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Table 2. Manufacturing Process And Material Used of Grass Cutting Machine (Continued…).
No. Part Name Material Process
16. Safety Guard Abs Injection Molding
17. Handle Abs Injection Molding
18. Handle Bracket Abs Injection Molding
19. Bolt M6 X 45 Carbon Steel Machining
20. Grip Rubber Injection Molding
21. Joint Pipe Aluminium Hot Extrusion
22. Screw M5 X 10 Carbon Steel Machining
23. Screw M5 X 25 Carbon Steel Machining
24. Stop Button Abs Injection Molding
25. Stop Button Bracket Abs Injection Molding
26. Throttle Lever Abs Injection Molding
27. Bolt M5 X 25 Carbon Steel Machining
28. Blade Carbon Steel Powder Metal
29. Shoulder Frame Carbon Steel Hot Extrusion
30. Lifting Metal Carbon Steel Die Casting
31. Shoulder Plate Holder A Carbon Steel Die Casting
32. Shoulder Plate Holder B Carbon Steel Die Casting
33. Screw M5 X 12 Carbon Steel Machining
34. Shoulder Plate Carbon Steel Die Casting
35. Bolt M6 X 16 Carbon Steel Machining
36. Engine Base A Carbon Steel Die Casting
37. Engine Base B Carbon Steel Die Casting
38. Cushion Rubber Rubber Extrusion
39. Rotating Shaft Carbon Steel Die Casting
40. Bearing Carbon Steel Die Casting
41. Nut M10 Carbon Steel Machining
42. Screw M6 X 12 Carbon Steel Machining
43. Fuel Tank Abs Injection Molding
44. Lid Tank Abs Injection Molding
45. Fuel Tank Band Carbon Steel Die Casting
46. Screw M5 X 20 Carbon Steel Machining
Fuel Pipe Protection
47. Carbon Steel Machining
Coil
48. Fuel Pipe Rubber Injection Molding
49. Bolt M6 X 16 Carbon Steel Machining
50. Fuel Pipe Clip Carbon Steel Die Casting
51. Tank Holder Metal Carbon Steel Die Casting
52. Engine Cover Abs Injection Molding
53. Screw M4 X 12 Carbon Steel Machining
54. Screw M4 X 10 Carbon Steel Machining

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Table 2. Manufacturing process and material used of grass cutting machine(Continued…).

No. Part Name Material Process
55. Rope Nylon Machining
56. Recoil Starter Body Abs Injection Molding
57. Starter Handle Abs Injection Molding
58. Starter Rope Reel Abs Injection Molding
59. Screw M5 X 12 Carbon Steel Machining
60. Cleaner Body Abs Injection Molding
61. Cleaner Fixing Base Abs Injection Molding
62. Cleaner Element Abs Injection Molding
63. Screw M4 X 25 Carbon Steel Machining
64. Clutch Case Carbon Steel Die Casting
65. Locking Pin Carbon Steel Die Casting
66. Fan Case Carbon Steel Die Casting
67. Screw M5 X 20 Carbon Steel Machining
68. Muffler Abs Injection Molding
69. Screw M6 X 65 Carbon Steel Machining
70. Plug Cap Rubber Injection Molding
71. Stop Wire Rubber Injection Molding
72. Engine Carbon Steel Die Casting

4. Result and Discussion

The assemble and dissemble process of existing design of the grass cutting machine will be identified
which parts to undergo redesign process and some part can be eliminated, minimizing, or combined
together for achieving higher design efficiency. The parts of the grass cutting machine are evaluated to
identify which part has a higher potential to be eliminate or combined. The parts are that not necessary
for the existing product of grass cutting machine can also be reduced. Table 3 has shown the assemble
of tank and assemble of exhaust before and after redesign.
The shoulder frame was improving the design of addition support to hold the tank for purpose of
minimizing the assembly time by eliminates 6 parts from current tank assembly. The tank holder was
design for extra support to hold the tank. By doing so, the number of part count has reduced with
minimize the time required for assembly. Thus, the design efficiency for the grass cutting machine
will be increased.
Next, the improvements were made to the exhaust assembly. The current exhaust assembly was
design with 4 parts and combination of three manufacturing process which is die casting, bending and
welding. The design is also quite complicated and can be increase the production time of assembly and
material cost. Therefore, the redesign of exhaust was made by reducing the manufacturing process
with eliminate the bending process. The production time for insertion between parts and material costs
were reduced simultaneously. There is also no impact on the function of exhaust.
Table 4 shows the comparison for the part quantity, handling time, insertion time, assembly time,
and design efficiency in between the existing design and improved design of grass cutting machine.

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

Table 3. Comparison between original design and redesign for grass cutting machine.
Original design Redesign

Quantity of part : 6 Quantity of part : 4

Quantity of screw : 4 Quantity of screw : 0

Assemble of Tank

Bending
process

Welding
process
Welding
process
Welding
Quantityofpart:5 Quantityofpart:4 process
Quantityofscrew:1 Quantityofscrew:0

Assemble of Exhaust

Table 4. Comparison Between Original Design And Improved Grass Cutting Machine.
Existing
Redesign Differences Improvement
Design
Part Quantity 72 61 8 12.50 %
Handling Time (s) 178.79 149.53 29.26 16.37 %
Insertion Time (s) 390.05 303.06 87.05 22.31 %
Assembly Time (s) 568.84 462.59 106.25 18.68%
Design Efficiency 26.4 % 34.70 % 8.33 % 8.33 %

From the Table 4, there is an increase in design efficiency of 8.33 %; this is due to 8 components
part has eliminated during the redesign process. For the percentage of part count, the result is 12.50 %
which considered as good outcomes as one quarter of total numbers of the components has eliminated
via the redesign process. Based on calculation, the result shows that insertion time being minimized is
more than the handling time, which are 87.05 s and 29.26 s respectively. For total assembly time, a
total time of 106.25 s is being eliminated. Therefore, the redesign is able to reduce the total production
time and minimize the cost by having less part count.

5. Conclusions
This paper presented the redesign of grass cutting machine by applying the manufacturing and
assembly design (DFMA) method [26-29]. It can be conclude that the design performance for grass
cutting machine of the redesign has been enhanced after the redesign process resulting in reduced part
count and overall assembly time. The design efficiency has come out of 26.4 percent of the original
design efficiency by 8.33 percent from the report. However, this is not the perfect possible
configuration for grass cutting machine, there can be a lot of change. The design consideration of the
function of the part and the vibration issue was important in order to prevent the performance of the
grass cutting machine. Therefore, some of the screws and bolt can be modified and eliminated by
consider the function of that parts.

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2nd Joint Conference on Green Engineering Technology & Applied Computing 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 864 (2020) 012213 doi:10.1088/1757-899X/864/1/012213

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