CHAPTER

Unit 5
5 Design ForX

Syllabus Topic : Design for Manufacture

Design for Manufacture

51
(SPPU - Dec. 15, May 16, May 17)

a.5.1.1
Explain the guidelines for design for manufacture, Design for assemble and design for environment in detai
(Ref. Secs. 5.1,5.1.1,5.2, 5.7 and 5.7.1) Dec. 15, 16 Marks
a.5.1.2 Explain the guidelines ofdesign for manufacture in detail.(Ref. Secs.5.1 and 5.1.1) May 16, May 17, 6Marks
Design for manufacture and assembly analysis is a part of design process and applied to many phases of product design.
t can be used in benchmarking analysis, simplifying new concepts which are not finalized, and simplifying fuly
embodied designs.
behind it is to reduce
Engineers have taken considerable efforts for integration of design and manufacturing. Intension
are known
manufacturing cost and to improve product quality. The different procedures and process that are developed
as Design for Manufacture (DFM)" along with "Design for Assembly (DFA)".

There are two components one is Design for manufacture (DFM) and another
is Design for assembly (DFA) combine it
is called as Design for manufacture and assembly i.e. (DFMA).
raw material. It involves application of part forming
DFM facilitates for making piece parts easier to produce from
simulations.
models, analytic formulas or complex finite element process
makes the simpler methods of attachment. It involves application
DFA facilitates for making attachment directions and
tables and motion and time studies in Industrial Engineering.
of attachment and complexity in models, time study based
it has three main
DFMA is very essential for design process because Major sections of DFMA system
it reduces cost and finally if
advantages. First it reduces part count, thereby
be produced in less time and is
esign is easy to produce and assemble it can 1. Raw Material
very cheaper.
various principles if we implement
DFMA is system which consists of
a
to easily
2. Machine and process
the ability for a design
principles properly it will improve
Zwwwwwwwscerra
ESe
of
essential to consider the principles
anufactured and assembled. It is very 3. Assemblies

DFMA during the design phase of new product development. Fig. C.5.1
There are three major sections.
L Raw Material
mechanical
material must have correct chemical and
material. Chosen
Found of good design is choice of right also consider cost while
uation use standard
material, if available. We should
We should
PEries as per design criteria.
sclecting the material.
2.
Machine and process with maintained quality of parts. Chosen process
should be
Main for production
DJective is to reduce the time required coolant and fixturing.
like tooling, finishing,
by considering all parameters
C
 Desig for X
5-2
Product Designand Dovolopment (SPPU)
Lgn should he simple. We should reduce total parts count. We should combine multiple parts. parts should he.poke
Assenblies
self
considerable time to untangle. Applv n
should be avoided
as they take
n d symmetrical. Tangling
of parts
vokr and mistakr proofing so that it can be casily and efficientl..
product is designed
developcd to ensure that a
DEMA is a set of guidclines
h time and cost.
manufactured and asscmbled with a minimum efforts, than that of conventional
are with high quality and reliability
roducts which are designed using DFMA principles
from the design phase to prOduction phase.
It also confirms smooth and rapid transition
ethods.
Why to use DFMA7
decreases amount of
Lower aKsembly cost: By eliminating unique parts and
use less nos. of parts it automatically
lahor for asembly.
2 It utilizes standard assembly practices such as vertical assembly and self aligning
Shorter Assembly timing:
parta
increment in reliability: It incrcases the reliability by lowering the numbers of parts and thus decreasing chances
3.
offailure
lt shortens total tüme required to take the product to the market.

Advantages of DFMA
1. t reduces numbers of parts and total parts count.
IT reduces assembly operation.
5. It reduces total lead time of product.
k reduces packaging time.
It reduces material cost.
6. Ii reduces overall Product cos.
II improves Productiviry and efficiency.
&. I improves quality and reliability.

5.1.1 Design for Manufacturability Considerations (DFM Guidelines)

(SPPU -Dec. 15, May 16, May 17)
Q.5.1.3 Explain the guidelines for design for manufacture. Design for assemble
(Ret. Secs. 5.1,5.1.1, 52,5.7 and 5.7.1) and design for
detai. environment in

a5.14 Explain the guidelines of design for manutacture in detail. (Ref. Secs. 5.1 and Dec. 15, 16 Marks
L Materiaks
5.1.1) May 16, May 17, 6 Marks
Design for Manufacturability
While thinking about DFM guidelines and materials Conslderations
taking
considerations we should first decide about whether material
in to
available in
standard stock configurations or not ? (1.e. in terms of bar 1. Materials
and standard exurusion).
stock, sheet www.am

AJso weshould hink about compatibility of material 2. Fabricated Parts

with chosen wwwwwwww.m
desirable manufacturing process. (1.e. ease of
forming, casting or
3. Product Assembly
mactining).
Moterial sgot is from reliable source or no1, whether Fig. C.5.2
the material
E
special alloys and special maler1als as per need
USibg price fluctuate widely with
time or not, when
of environmental factors or
2 . Fabricated Parts tunctional demands.
inkine about fabricated parts we
OUld Consider whether parts
special proCesses and special tooling. configuration minimize the neea or
 DesIgn and Development (SPPU)
nand Develo

5-3
ooduct Design forX
urfaces,
es, data points
data point and tooling points
are
apability of manufacturing process to beclearly
Whether

within n o r m a l
accessible or not, whether atainable tolerances lie
used or not.
ProductAssembly

deals with series of issues related to

assembly, whether the parts
can go for tes thout are easily accessible for assembly or nol,
w/hether
we
disassembling the product or not.
Alsoithighlights about internal wiring whether the intenal wiring is critical or simplified.
ASO ical wiring then whether the location and
critical
fit is
a
and connecto
and connectors or not. lt also deals with
routing is specified or whether we
not, we are using standard
asembly hardware
hardware
complete and definitive notes of assembly.

Syllabus Topic: Design For Assembly (DFA

Design ForAssembly (DFA)
(SPPU-Dec. 15, Dec. 16)
Explain the guidelines for design for manufacture. Design for assemble and design for environmentin detal
621
(Ret. Secs. 5.1,5.1.1,5.2, 5.7 and 5.7.1) Dec. 15, 16 Marks
sa? Erplainthe guidelinesfordesign for assemble.(Ref.Sec.5.2) Dec. 16, 6 Marks
Definition- DFA Guidelines

a set of instructions if we will implement it we will get a fare analysis. These

design with detailed
DFA guidelines is for ease
m:rions are categorized further as system design guidelines, guidelines for ease handling and finally guidelines
fmachment.

Guidelines
different functions in to single function.
Nurmber of part count in assembly should be minimized by combining
sub assembly.
Different parts should be combined in to single
should not carried out in closed space.
We should perform assembly in open space, It
Detect the it's orientation for insertion.
parts regarding
Parts should be standardized to reduce the variety.
Maximum numbers of parts should be symmetrical.
properties.
the parts are non symmetric then design in terms of geometric
Remove the tangling parts.
coded.
Diterent parts but with similar shapes must be color
Avoid the nesting of parts.
non-symmetrical parts.
Uenation features should be given to insertion.
aing parts should be designed for sack of easy
3.
Alignment features should be provided.
New parts in the sembly should be inserted from above. be turmed over.
never
15. This should
insertion should be in same direction, and assembly
Fasteners should be removed.
Location of fasteners should be away from obstruction.uniform fastening8
and
9. portions should be provided for sack of casy of accurate spacing.
with the help
Allowance0for Tastening
. For sac i tools should be provided
channels should
be sufficiently
wide.
the deep
y access of fastening tools
System Guldelines such a way hat part
function can
instead be performed by
in
h
this part modularity.
set of guidelin
0 R u i d e l i n e s ,

detect each and every ld he reduced through assembly

 5-4
Design tor X
together into single board so
LProductDenign and Development (SPPU combined that it can
assemble
should be be
and
riarts which are difficult
to manipmla
The from outer side, parts which require
nner fasteners
ealy manipulated and nsuemhled assembled
that it can be
in such a way
esigned alignment of asse
wthin enc lure showld he strictly avoided.
should not
be any
need of precise process,
so that there
ve self lncking property
avoid the
of
chances eror
facteners will
such as
u r e
pan family items

parts from the

The
e
Handling guidelines
parta which we a r going to aseemble
must be handled.
Handling
includes

to assembiy
for
taking the

insertion and orient the location

s for
we are going
the point where
parta fmm location
to
Ey these

sembhy avoid unnecessary

orientalion. metric parts sho
Asymmetric parts
should b
nature so as to
NIUm parts should he symmetrical in the
combined for nack of eaxy orientation. with each other. There should be
tangle or stick
that they should
not proper
part should be designed in such
e a way
means.
non geometric
diferentiation of parts which are shaped similarly through c h a r a c t e r i s t i c s . Nesting of parts shonla
the parts with orienting
ald
Anymmetresin the can he matched
parts by designing
be avoided

Insertion Guidelines
characteristics should be provided on assembly so
We should chamfered parts for sack of casy insertion, alignment
use

that new parts can be easily oriented without measurement.

There should be proper placing and maintaining the parts
for fastening against gravity. Procedure of assembly should be
one side.
done only from the top, and fasteners should come in only from
First part should be wide and stable enough then assembling of smaller parts should be carried out sequentially.

f we are unable to assembie the parts in top down direction then we can implement insertion directions.
Enure assembly must be compieted on single surface and proper assembly sequence must be considered.

Joining Guidelines
Insered parts in the assembly must be closely atached with the help of joining process. This can be done with the bep
af some faseners, adhesives and welds. There should be minimum numbers of fasteners.
Assembly of parts should be designed as per the instructions of the fasteners.

Theoretical Minimum Numbers of Parts

I is very imyportant to realize the fact about assembly is that we should combine multiple parts in to single part on a
singie platíorm. We must simplify our design by removing all unnecessary separate parts.
There is no any betier option of simplifying the assembly step than to remove it.

Syllabus Topic: Design for Robustness

5.3 Design for Robustness

(SPPU May 16, Dec. 16, May 17, May 18)

a.5.3.1 Discuse design for sobustness in detail, (Ref. Sec. 5.3)
What are guidelines for design for robustness? Discuss. May 16,8 Marks
a. 5.3.2
(Ref. Sec. 5.3)
Marks
a. 5.3.3 Explain guidelines of design for robustness and satety, (Ret. Sec8. 6.3, Dec. 16,5 Marks,May
May 17, 4
18,8Marks
May 18,8 5.4, 5.4.1 and 5.4.2)
Robust design is o elect the best set of nominal
configuration
cnecifications with mininuim oE Vlaun due 0 anulacture, parumeters which satisfies the P
ance

material or use VArintions

ie concent of robust debigo givs abburau ADDUt
CIgineering quality and ideas of customer. custon
 eian and Development (SPPU)
5-5
oformation, materials, energy to produce the
Paduca

infon
u s e s

Gcation with the help of or in terms of Design for X

y petomance
The
Product

specifi output. Difference between

performance variables. input and output is
thing but desired output which is to be measusured
ntimea the designer. To achieve this
objective
choice a proper Different uses
designer
product and settinggs
figuration
along with parameters like complete
nal description, :
dinension manufacturing description
andmaterials

meters are termed as design variables.

efective design variables is the job of Material and Product
(honce

s k i l e de n g i n e e r . manufacturing configuration Performance

variation (which acts as variation
ertain factor due to which there in variation transfer function)
performancee variables. This factor may be
inthe
in to the manufacturing process, difference
working environm and deviations in the
h the
erations ofproduction.

hese factors are responsible for not getting the Design cofiguration
selection
cired targeted performance of product. These
Uses of variation are noise variables. Fig. 5.3.1 :Factors that can change Delivered Performance
ne main objective of robust design 1s to prepare a product model with performance, noise variables and design and
hen
we will use that model for improvement of design by selecting a design configuration which provides low

erformance deviations with free noise variables.

There are three phases of robust selection process, Product performance
during use
o First step is to construct the model. After constructing
the model we should detect design variables,
Material and
performance and noise.
manufacturing Product Performance
variation variation
oAfterthis as the noise varies performance variation configuration
must be measured there should be repetition of this (which acts as
transfer function)
step for different design configurations. Operation variations
0 After this we will come to know about that design
configuration which has less performance variation all Change the
Measure the
for same in put variation. variationsS
configuration
For each we will take this set of
product configuration
erfomance measurements and we will reduce them to
Robust design
Uge rating for the design configuration. Finally we will optimization process
ect most robust configuration based upon robustness Fig. 5.3.2:Overview of Robust design Selection
rating
Construction of Robust Design Model
behind variation, how to measure its effect
Fustst tection of determination of variation problem, what is the
reason

ha
dwhat can be done about it?
2surement of Performance Variables
should be effective
To prepare should consider right performance criteria. There
obust product design team
Pero
eomance variables for robust design. of both design and noise variables.
criteria of varying performance
should be continuo physical operative uous
of failure mode, should detect failure we

hshoul
ode(F
d be in metric is
performance metric, and this performance
measure

- Failure ode Effective Analysis Technique). consider the

Thet we should abo
u d think about what we can
measure with units to represent
this failure. We should also

em
performance of product.
 Design for X
Product Desipn and Dovelopment(SPPU) 5-6
representations. Perfo
formance met
structures and analytical
In that we should consider system models, functic macnine as 1ar as
E.g. In case of honing customer
which incude sclecting variables that should be casy to measure.
through honing machining.
amount of roughness on
processed material
ctric of lormation
of small
Here perfoTnance metric is small amount of roughness to evaluate robustness

Causes of Variation : Nolse Variables

we consiaer three types of
to cause variation in the performance.
NCAI sIep is to detect variables which are responsible
noisc which can he cxpected in product development.
internal noise due
variables. Creation ot to
Manufacturing noise: These are manufacturing variations on product
manufacturing
niernal noise: These product variations are caused due to degradation or depreciation. E.g. wea
and other environmental
External noise : This is due to external factors like user interaction, variation in temperature
factors.

Specification of design variables

Tbe final step in construction of robust model is to detect variables that are available to specify. If we change it we can

of the output performance variables to the input noise variation. We can observe input output transfer
educe the Nensitivity
mechanisms and examine them for variables.

Syllabus Topic: Design for Safety

5.4 Design for Satety

(SPPU - May 17, May 18)

a.5.4.1 What are guidelines for design for safety ? Discuss and elaborate.
(Ret. Secs. 5.4, 5.4.1 and 5.4.2) May 17,5 Marks
Q.5.4.2 Explain guidelines of designtorrobustness and safety.(Ret.Secs.5.3,5.4,5.4.1 and5.4.2) May 18.8 Marks
Safety is an important issue in product design. We take safety as granted. Unsafe products can be very costly in terms of
product liability and product reputation.
The product must be safe to manufacture, to use and to dispose off after use. If serious accident happens in which life
can be lost this situation may lead towards ending of career of responsible engineer.
A safe product is that which does not cause injury or property loss. It also includes injury to environment. Safety cannot
be achieved accidentally.
We should concentrate on safety during design. For that purpose we should know some basic rules.
There are three parameters to design for safety.
1. Prepare the product for safe. We should design the product in such a way that all hazards should be out.
2 1If is not possible to prepare the product completely safe then design should include protective devices like
auiomatic cut off switches, guards and pressure relief valves to eliminate hazards.
3. If we are unable to remove all hazards in step two then we should warn the user with appropriate warnings ike
Labels, flashing lights and loud sounds.

5.4.1 Fai-Safe Design

(SPPU -May 17, May 18)

a.54.3 What are guidelines for design for safety ? Discuss and elaborate.
(Ret. Secs. 54, 54.1 and 5.4.2)
May 17,5 Marks
a.544 guidelines
Exolain of design for robustness and safoty, (Ref. Secs. 5.3, 5.4, 5.4.1 and 5.4.2) May 18, 8Marks
that failure will
tis the design which ensures neitheraffect the product nor change it to state in which no
a

damage will occur.

a
injury
Poouct

offal-sate Designs
Design for X
1 y p e so f
f a l l k s a t e

Fail Passive design

Types of fal-sate Deslgns
when a failure the
Inthis
gn system attains its lowest
product
lI not
will not operate until corrective action is taken, energy state and 1. Fail Pas8ive design
the e.g. Circuit breaker
Fall Active Design
2. Fall Active Design
2

failure
Occurs the syster remains energized and in a
when safe 3. Fall operational Design
Redundant
system kept on
standby. operating mode.
e
Fall operatonal Design Fig. C.5.3
ign the device continues to provide it's critical
Inthis
function even though a
part has failed.
Potential Dangers

ration and Deceleration : Impact Damage, Falling

Acele

object
Contamination: Human exposures, Material
Chemical

degradation.
Flctrical:Shortcircuits, bun, shock
Epvironment: Fog, humidity, lighting and wind
Explasions: Dust,explosive liquid, gases, vapours.
Fire : Fuel, combustible material
Human errors

Leaks or spills

Radiations
I0. Mechanical Vibrations
1. Temperature.

S42 Guidelines for Design for Safety

(SPPU May 17, May 18)
54.5 What are guidelines for design for safety ? Discuss and elaborate.
(Ref. Secs. 5.4, 5.4.1 and 5.4.2) May 17, 5 Marks
54.6 Explain guidelines of design for robustness and safety.
May 18, 8 Marks
Ref. Secs.53,5.4, 5.4.1 and 54.2) not affect its function.
the product so that it will
ACDgnIse and detect potential hazard and accordingly design
the carefully to reveal any hazards
overlooked in the initial design of product.
tamine prototypes
DEsign the product so that it is easier to safety than unsafely.
hazard.
4 and redesign to eliminate the
then determine the root
cause
ystage problem occurs
the products user friendly.
the errors completely. prepare
reduce the human errors, try to avoid
and
Product shoul be designed by considering both ergonomic and safe desig.
material.
We u d use minimum flammable material with
including packaging
toxic in nature. It should be safe when
using it should be
non

Whatever paint and other surface finishing material we are

Durnl, recycled or discarded.

9.
Wes ould think about need of repair, maintenance and service.
lectrical products should be properly grounded to avoid shocks. useful for engineers.
1. Wherever net warn for safety. It is very
used to
cessary warning labels should be
 Design for X
5-8
Product Design and Development (SPPU)
for Reliability
Syllabus Topic : Design

5.5 Design for Reliability

5 Marks)
Discuss in detail.(FRet. sec:o
d..5.1What are the guidelines for design for reliability? he
extreme approacDes
reliability can fall between two
ne design methodology used to ensure

1. Fail-safe approach

2. Absolute worst case approach

5.5.1 Fail-safe Approach

some arrangement to monitor that
component. We will provide
approach is to detect weak spot in the system
or
his

weakness board. The objective of this

in energy electrical supply
h e weak ink is replaced as we replace the fuse in household
will operate on its full range till the
have equal life so that the system
design is that all components in the system should
end of its useful lifetime.

5.5.2 Absolute Worst Case Approach

Design should be based on the platform that "all go
In this approach we should detect worst combination of parameters.

wrong at same time". We should make provision for reliability during the design concept stage.
Steps in Buildingthe Reliability
criteria for successful design. We should
This process initiates at the beginning of conceptual design by laying out

estimate required reliability, duty cycle.

As a part of embodiment design physical arrangement ofa part should be considered. Detail design is the place for final
revision of specification.
For building and testing we go for preproduction of prototype and hence preparation of final production drawing takes
place.
Thus formed production models are further given for environmental tests and it help to establish quality assurance
program.
When the product is active into service with customers then there should be steady feedback relating to the field of
failure.

5.5.3 Causes of Unreliability

1. Design mistakes (Wrong calculations, poor material selection)

2. Manufacturing defects (poor working environment and training)
3. Maintenance (improper performance)
4. Exceeding design limits (limits of temperature, speeds)
5. Environmental factors (rain, humidity and ice)

Table. 5.5.1: Different design stages and activities involved in

reliability activity
Design stage Design activity
Conceptual design
Problem definition- Estimate reliability requirements- determine
environment service
Configuration design - Investigate

redundancy Provide accessibility for maintenance

-

Embodiment design
Parametric design Select highly reliable
-

component full environment

establish failure modes- User trial modification tests
 Product Dasian and Development (SPPU)
DeSign

5-9
Design stage Design for X
Produce and test Designactivity
Detail design
Final estimate of preproduction prototype
reliability
Production model further
Production
program environmental tests- establish quality assurance
Deliver to customer
Service
repair and replace
-

Retirement from service

sign Practice
to Improve Reliability
Hesbould maintain margin ofsafety during the use of product to avoid the failure.

The analogy of using factor of safety is

herating:The derating of components.
maximum operatng condition are derated below their nameplate Reliability of such a equipments is increased
imaro

hility: We should select the material and design details by keeping in the mind objective of the production system
Durabili
resistance to degradation from factors like Corrosion, fatigue, depreciation, wear etc.
thatisr

BeofInspection: Design prepared should be easier for inspection

Simnlicity: Design of product or assembly should be as simple as we can in order to reduce the errors.

5Costof Reliability

Cost

Total cost

Cost after delivery

Cost of design
and manufacture

Reliablity

Fig. 5.6.1:Cost versus Reliability

reliable components,
associated with designing and producing
more
Ihe o
o f from extra costs
si
reliability comes
eability and training and maintaining a reliability organization.
The0St
cos of reliability.
design and manufacturing increase with product with increase in the reliability.
The costOproduct after delivering to customer, the replacement cost decreases
for Environment (DFE)
Syllabus Topic: Design

Design for Environment (DFE) (SPPU -Dec. 15, May 18)

environment in detail.
design for
87.1 idelines for design for
Explain the guid
manufacture. Design for assemble and Dec. 15, 16 Marks
Secs. 5,1,5.1.1, 5.2, 5.7 and 5.7.1)
L572 e,
Discuss for design for
environment and materials detail.
in
May 18, 8 Marks
guidelines (6 Marks
Ref. Secs. 5.7 and 5.7.1) Sec.5.7)
673 hat design for
environment? (Ref.
ectives and need of
are the object
 Design for X
4Product Design and Development (SPPU) 5-10
intluenced in the early desin
essential for team, Damaging of
environment is greatly
DFE IS an
activity design
a
is established after 20% of
as in case of production cost 80% of a cnvironmental
damage of a product
pnases. Example,
the design activity is complete.
the World is becomino
As the population of
customers are asking the product with less environmental impact.
day s Hence we should creale a product which is
aware of influence of society thus society is trying to minimize its impact.

having less impact on the environment and it will popularized the market.
reduced environmental impact standards for
Govemment agencies are also forcing their constituents to develop
for environment practice. Many countries
products. They are also developing the standards which will support design
such as packaging, computers and
have made it compulsory to post use buy back requirements for products
-

transportation of vehicles, complete with required recycling of components.

Now a day's customers are demanding environmentally friendly products reason behind it is there is generation of
several types of pollution. Thus it is important to realize these pollution types and its impact. And also we should think
about what can be done in the product development process to eliminate impact of these pollution types.

5.7.1 DFE Guidelines (Environmental Objectives)

(SPPU - Dec. 15, May 18)

Explain the guidelines for design for manufacture. Design for assemble and design for environment in detail.
Q.5.7.4
(Ref. Secs 5.1,5.1.1,5.2, 5.7 and 5.7.1) Dec. 15,16Marks
Q.5.7.5 Discuss guidelines for design for environment and materials in detail.
(Ret. Secs. 5.7 and 5.7.1) May 18,8 Marks
1 Protection of biosphere

Companies will try to minimize the release of pollutants which DFE Guidelines
will put the earth in danger. (Environmental Objectives)
2 Optimum use of resources
1. Protection of biosphere
Companies will use raw material at optimum level where they
can be sustained
2. Optimum use of resources
3. Reduction and disposal of wastes
3. Reduction and disposal of wastes
Wherever possible companies will minimize the waste. If they
cannot avoid the waste they will adopt the strategy of recycling.
4. Optimum use of energy
4 Optimum use of energy
5. Reduction in risk
Companies will go for investment in energy conservation. They
will prefer environmentally safe energy. 6. Marketing of safe products and services
5. Reduction in risk
7. Damage compensation
Health risk to employees and the community will be minimized
by the companies. 8. Disclosure
wwewecco.xeAEKOSN
6. Marketing of safe products and services
9. Environmental Directors
Companies will adopt the policy of he marketing the products
which wil minimize environmental impacts and are safe for 10. Annual Audit
consumer to use.
Fig. C.5.4
7. Damage compensation
for any harmful effect on
Companies will be responsible environment. Responsibility he
harmful effects will be hold by the company. to clean and compensa
 Design and Development (SPPU) 5-11
&Disclosure
Design forX
which result in harm to
Incidents environment or which will create
disclosedb campany to employees and the
community. safety or health hazards must be
Eav
nvi
i ronmental Directors explained or

4 seniorexecu
.tive member from the company will
be
menmberfrom company board will be nominated to looking in to the matters of environmental
represent interests in the affairs. At least one
10. AnnualAudit environmental issues.
a
check t orocess of "How these environmental
o che policies /
ns by the company. Companies will also Principles are being implemented ", there will be annual
prepare result copies of environmental
Vailable to the public. audits. They will makeeit
DFE Guldelines
, A Basic DFE Guidelines for Material Selectio DFE Guidelines

Never use regulated and restricted materials.

1 Numbers of various types of materials should (A) Basic DFE Guidelines for Material Selection
be Minimized.
(B) Basic DFE guidelines for Product structure
3Avoidcomposite materials

4. Use recyclable material (C) Basic DFE guidelines for Labelling and Finish
5. For moving parts high strength to weight
materials should be used.
(D) Basic DFE Guidelines for
Fastening
6. Use low alloy metals.
Fig. C.5.5
(B) Basic DFE guidelines for Product structure
1. Multifunctional products should be designed.
2Minimize the numbers of parts.
i Avoid separate
springs, pulleys.
4 Make designs as modular as possible.

5. Avoid embedded metal in plastic parts.

6Whiledisassembling, parts should be stable, accordingly Design the parts.
1.
Specify reusable containers for shipping.
C)Basic DFE guidelines for Labelling and Finish
Use electronic part documentation.
Unplated metals are more recyclable hence they should be used.
S.Eliminate incompatible paints on parts.
ink should be compatible and comfortable while printing on the parts.
D) Basic DFE
Guidelines for Fastening
Minimize the numbers of fasteners.
.
quirement of the numbers of fastener removal tools should be minimized.
Fasteners should be easy to
4 Fastening oints should be removc
to access. easy
S.Wes
6
uld locate snap fits and it should be
able to torn apart using
standard tools.
with each other.
wo parts should parated if these two parts
be separ can not be compatible
1. Elim
e adhesives unless compatible with both parts joined.
e the number and length of interconnecting Wires.
 Deign
Product Design and Devekpment(SPPU 5-12

5.7.2 Design for Recycling

(5 Marka)
a.5.7.6 Explain thedesigntor recycling (Ret. Sec.572) that there for the malerial. o we should ue
must be demand
Fint requirement for
recycling a materíal in a product is
commonly recycled material such as metals and plastics.
Each product component should be rated on recyclability and separability.
and separability
2 Rating should be given for each component based on recyclability
3 The component is recyclable if the both rating are lower than 3.
ratings for each subassenbly and for the
then be combined on a mass or value basis in to
The Individual ratings can

product as whole

5.7.3 Design for Remanufacturing

5 Marka)
a.5.7.7 Explain the design for remanutachuring. (Ret.Sec.5.7.3) are disassembled can be easily
product so that it's component
Desugn for remanufacturing is where one designs a

cleaned and inspected.

is taken to a central facility and disassembled. Heze
2 Remanufacturing is an end of life strategy where the product
some extent and then inspected
Tterest is not in the recycling of the material content but the parts are sorted, cleaned to

3 There are three seps used in Remanufacturing.

shape it is rejected. It is
Step I: Visual Inspection: It is simply visual inspection for disposition. If the product is in bad
simply go. no-go visual judgment.
Disassembly of the product: Here we disassemble the product in to sub
sets that can potentially recycled be or
Step 2: reused. This step includes labor hence it is costly so design decision is made to simplify this process. One can make
or break effectiveness of the step.
Step 3: Ceaning and inspection: Parts that are to be remanufactured must be returned to a new condition and their quality
assured

Syllabus Topic:Designfor Piece Part Production

5.8 Designfor Piece Part Production
a.5.81 xplain the concoept of piecepartproduction. (Ref. Sec. 5.8) 5 Marks)
DFA is omly one aspect of easing the manufacuring. The other aspect is to make each part easy to produce. It is very
difficult to formulate general design guidelines. It is really simple and easy to align guidelines with the processes used
1o make each part.
She metal DFM guidelines are not related to plastic part DFM guidelines. The best
way is to consult production
engineer in the process to be used and ask them for advised on the design of the part.
We have guidelines and design analysis tool for many processes in that sheet metal
parts have guidelines for minimum
bend radii and feature separation. Cast parts have recommendations for feature locations to
during mold fill
provide materials flow paths
Machining operations have guidelines on dimensions and tolerance. It is
impossible to
production process however new refined process is constantly under development. provide guidelines for every

5.8.1 Cast Part Design Guldelines

(SPPU-May 17, May 18)

a.5.8.2 Explain the guidelines for design for castng. (Ref. Sec. 5.8.1)
May 17.5 Marks
a.5.8.3 Discuss guidelines of design for castingand lorging. (Ref. Secs.5.8.1 and 5.8.2)
Avoid sharp corner.
May 18.8Marks
1.
mold.
2. Provide a draft angle to help removal a
thickness.
3. Maintain uniform section
hProduct
Designand
Develc
nent (SPPU)
5-13
Non-unifor section thickn
ckness causes hot
spots which will Design for X
h o ts p o t s
produce shrinkage defects.
Avoid
abrupt changes in sectio thickness. Design
gn T junctions to roduce
part of the casting which
produces tensile stress which
Don't restra

bosses with uniform thickness. can result in hot air.

Design
Machined Part Design Guidelines
h82

Discuss guidelines of design tor casting (SPPU - May 18)

a 5.8.4
and forging. (Ref. Secs. 5.8.1 and
holes to the shapeof tool. If 5.8.2) May 18,8 Marks
Design hole is to be tapped provide space for it.
Use standard dimensions

Donot design
impossibl to machine hollows
holes
Avoid long
narrow

Design for reasonable internal pockets radii

Avoid thin walls that break while machining

1 Avoid drilling inclined Faces

Place holes away from corners and edges.

Provide easy access for tools

10. Design parts that are easy too fixture

Syllabus Topic: Manufacturing Cost Analysis

5.9 Manufacturing Cost Analysis

(SPPU - May 17, May 18)

a.5.9.1 Discuss in detail manufacturing cost analysis. (Ref. Sec. 5.9) May 17, 6Marks
.5.9.2 Explain manufacturing cost analysis. Explain stepwise procedure for estimation of cost.

(Ref. Sec.5.9) May 18, 8Marks

Selling price

Manufacturing Distribution Retail cost

cost cost

Overhead
Piece parts
Assembly

Custom Tooling
OEM parts
Labor
parts

Set up
Processing
Material Tooling
Breakdown
Production cost
Analysis
Fig 5.9.1:
 Desi for X
5-14
Product Designand Development (SPPU) to decide
portion of a design
what
is more appropriate
it is important this basic product cost
To realize the cost structure of designed roduct concepts. For
comparing different design
o r detailed cost reducing design activity
and for of the cost
model including part costs and

for the various portions

followed by cost models
accounting will be covered
assembly costs. how the product
is used to determine
philosophy covers cost analysis which
Ine design for manufacture and assembly the Major cost is
due to material procurement, part
competition. Rise in
delivery major costs compare with the
production, assembly or finished product delivery. of a few kev
for assembly simplifications
we can achieve 80% of the possible cost
reductions through the design
bidding on expensive purchased
for manufacture redesign of few expensive components and adequate
system, design
original equipment manufacturer (OEM) components.

Cost Driving Modelingg

and dispose of outputs to the manufacturing
Manufacturing cost is the sum of all expenditures to purchase inputs
efforts, energy, equipment, maintenance
systems. This includes raw materials, purchased components, employee's
materials, and plant disposal costs.
cost which is total manufacturing expenses over a period
A metric of cost commonly used is a unit manufacturing
divided by the number of units produced during that period.

Manufacturing cost accounting

Manufacturing cost accounting9
Manufacturing cost breakdown consist of
1. Piece part costs
This includes the cost of both parts made and bought from suppliers. 1. Piece part costs

2. Assembly costs 2. Assembly costs

This includes the costs of assembling the parts in to the product.

3 Overhead rate 3. Overhead rate

This covers the costs of supporting direct production of parts and assembly. Fig. C.5.6
This includes only the cost of producing the items.
Categorles of part costs
Cost Modeling
The basic approach that we will consider for cost modeling of different
manufacturing process is to consider cost drivers. Cost driver is a process which 1. Material costs
decides the cost of the process. We will consider part costs in three categories
ie. material cost, tooling cost and production cost. 2. Tooling cost

1. Material costs 3. Set up costs

These are the costs of the raw materials for the part, generally expressed in
Price per pound. 4. Processing cost

Material cost per unit = Part weight x Scrap x Material cost/lb Fig. C.5.7
2. Tooling cost

These are the fixed cost to buy the equipment to convert the material in to finished part or component.
The cost include the cost to design and fabricate the tooling.

Tooling cost per unit =

Equipment costs / Parts per equipment
3. Set up costs
These are the costs to set the machines up to begin a batch of production.

4. Processingcost
These are the labor and maintenance costs to keep the equipment running.

Processing cost per unit= Labor rate per hour x Hours per unit
 Product Design and Development (SPPU) 5-15
Similarly Design for X
Assembly cost per unit =
Labor rate per hour x Hours
per unit
Manufacturing Cost Analysis
Categories of cost analysls
In detailcost analysis can be
performed at different levels. There
caiegories of cost analysis. are three

1 . Level 1:Estimate Level 1: Estimate

It is the first
impression by a knowledgeable engineer. HE will estimate about Level 2: Analysis
part, assembly or system cost based on his prior
less than 10 minutes of work
experience. This would involve Level 3: Cost accounting
for a
system of 50 and is
within 20 parts generally accurate
Fig. C.5.8
2 Level 2: Analysis
estimate, which is based on break downs of cost and itemized cost based on
It is
Different parameters for estimation are prior experience with similar products.
budgetary estimate, vendor quotes, expert opinion and experience. It will take a
day of work for a system of 50 parts and is generally accurate within 5%.
3. Level 3 : Cost accounting
It involves detailed costing of each and
every part used for material cost estimation data bases and ime or motion
studies. If we will compare and
accordingly perform to industry standards and request for vendor quotes, we will get
high degree of accuracy. It will take a week of work for a system of 50 parts and is generally accurate to within 1%.
Many manufacturers have cost analysis teams that provide their product development teams with level 3 cost analyses
of their competitor's product.

Syllabus Topic:Local, Regionaland Global Issue

5.10 Local, Regional and Global Issue
(SPPU -Dec. 15, May 16, May 17)

.5.10.1 What are local and regional issues for environment ? Elaborate. (Ref. Sec. 5.10) Dec. 15, 8 Marks
Q.5.102 Discuss various regional and global issues of environment pollution.
(Ref. Sec.5.10) May 16,8Marks May 17,6 Marks
5.10.1 Local, Regional Issues Problems occur at reglonal level
More environmental problems occur at regional level. These problems are
acid rain, air pollution and water pollution. Acid rain exists due to pollution by 1. Acid Rain.
products in one region can cause acid rain in another region. Air pollution and
smog are also regional problems. Water pollution occurs in the river, ground 2. Air Pollution
water, bay or ocean, is also regional problem. It is caused by pesticides and street
water runoff in the suburban and urban area 3. Water Pollution

Fig. C.5.9

Acid Rain
It is a regional pollution problem which is caused by excessive fossil fuel air emission for a regional area. These
fuel combustion products get released into the air and cause rain in surrounding environment to have lower acidic
PH level.
Which can cause hazards to regional plants and aquatic life also get suffered. As far as product design is concerned
reduce this problem.
development of product which use less energy it will help
to
 2 Product Design and Development (SPPU) 5-16 Design forx
2. Air Pollution
area. Ozone, carbon monoxida
emissions for a regional
problem caused by excessive fossil fuel
It is a similar
which are released into th
fuel combustion products the
nitrogen compounds, sulphur dioxide are common problem
air.

Development of products which will use less amount of energy will help to eliminate this problem
3. Water Pollution
Water pollution is another source through which contaminants can enter in the environment through water flou

streams and landfills.

Pesticides and herbicides are problematic compounds whose amounts introduced to a regional area must be

controlled. Other chemical compounds that are used in the products must be realized and controlled.
5.10.2 Global Issues
Pollution problem which
There are certain pollution problem which affect a global scale. These affect a global scale.

problems include climate change, ozone depletion layer and biodiversity

loss. 1. Climate change
1 . Climate change
2. Depletion of the Ozone layer
Due to increase in green house gasses there is large dramatic
climate change in earth's climate. This issue is mainly because 3. Minimizing Biodiversity Loss
usage of energy percentage of carbon dioxide in the atmosphere wwwwwww s wwwwweu

gets increased due to burning of fossil fuels. Fig. C.5.100

There is rise in the temperature of atmosphere, global surface of earth, ocean due to this increased percentage
carbon dioxide in the atmosphere which results in drastic climate changes.
As far as product design is concerned we should develop the product which will use the energy and it will help to
eliminate this problem.
2 Depletion of the Ozone layer
The ozone layer prevents ultraviolet radiations of sun from reaching the earth surface. It is a thin layer which is
present in the upper atmosphere. Reduction in the ozone layer is due to as fluorocarbon gasses.
Many industries release this fluorocarbon gas. In product design while developing the product we should take care
about release these harmful chemical, gases while using, manufacturing or making disposal of product. It will help
to eliminate this problem.
3. Minimizing Biodiversity Loss
This issue also globally Impacts on environment. It includes loss of habitats for
different plants and animal species
due to expansion of our society can cause loss of echo system and extinction
of species.
In order to eliminate this problem we should develop such
products that use less new raw material.
Syllabus Topic: Basic Life Cycle Assessment Basic Method

5.11 Basic Life Cycle Assessment Basic Method

- -

(SPPU -May 16)

Q.5.11.1 lifecycle assessment? Explain any one method in
What is
detail. (Ref.
cciety of toxicology and chemistry has developeda four step process forSecs. 5.11 and 5.12) May 16,8 Ma
nrocess helps us to realize impact
or a proauct irom
manuracture
completing a life cycle assessment.
through use through disposal, This process includes
following steps.
Sten1: Goal Definition: This step des consideration
of environmental assessment in to
hiectives. A company may wish to reduce CO2 product iesign in order
des
emissions, meet certification, reduce energy
reduce component toxicity. Thus the goal should be clearly defined and
use,

be meeting eco labelling requirements, meeting regulations revisited. Some common may
objectiv
POdUcID8,

verall prodi function: A:After

5-17
alvsis. It involves alldefining the goal the next Design for X
em define overall
activities and step of
design a
ssenu
is esser
operations in the
product function often team is to cstablish the
boundary of the
and what is it's called product life
environmental impact. Thensystem function in cycle.
of
theproduct
After definit
ining the bounda it
functional unit. LCA
c establishtal
a
with the
help of over allliterature.
must What is the purpose
vironmental
Impact Inventory: After product
product function designt eam
Which involves sequence defining the goal then
activities each called
Whiche and produces desired a life
cycle
scope of produc
duct system should be defined.
cnergy

activity out come stage. Each life

impact inventory deals with how
ntory deals how much of
the
along with waste materialcycle stage takes in materials and
*

energy con: imed and and energy. This environmental

pollution generated whilemanufacturing process will be considered,
for disposal. Can
Can we go for removing the raw all the way back o
material.
different impact on the recycling? What
available
What are the different
rameters have is the
energy utilization patter options
: Impace Assessment: After studying the
environment pattern of product. All these

basic
system there should be
are having two methods
to carry out
the impact assessment of each step in the
analysis: 1. system. we
2Weighted sum assessment method.
Environmentally responsible product assessme
Process materials, reagents
solvents and catalysts
and (including reuse
recyce from another stage)
Energy
Reuse/Recycle this stage

Product material inputs

(including reuse and recycle
from another stage) Single product Reuse/Recycle for a different stage
stage
or Primary product
Operation Useful Co-Product

Reuse/Recycle Fugitive and| Treated

this stage untreatedd waste
waste

Fig. 5.11.1 : Life Cycle Stage

Eavironmentally responsible product assessment method does not complete a numerical LCA. In this method
estimates of environmental impact are applied. Whereas the Weighted sum assessment method assigns numerical

mpact the materials and processes we use. So these methods discus inmpact on environment
weightings against
and calculate it in terms of numerical value or estimation.
be discussed
interpreted for opportunities to
completing the assessment results can
or
4 Interpretation: After
and to compare amongst available alternatives. We can
Change the design to improve the environmental objective
on environment.
reine and explore design choices which are having high impact

11.1 Cycle Assessment Method (LCA Method)

Here we consider actual environmental impact
complete analysis of environmental impact.
numerical
Here we are not considering the average
Consider and disposal system used.
Ing the actual production system, operation
Values of
regional impact. the life cycle of a product is
In this that occur from all processes during
method
Eod an inventory of all emissions
and all wastage generated.
d in to a list of all emissions released,
all raw material used
2Product Design and Development (SPPU) 5-18 Design forX
are decided for the
actual product as well as emission
For each of these steps, the energy and raw material requirements
are then summed
with appropriate units.
levels produced. The values of each stage of the product's life cycle
is reserved for
in the nature. Currently this analysis
LCA result is accurate, complete, comprehensive and expensive
This LCA technique is continuously developing
high impact materials like chemical film products, medical products.
and hence there is reduction in the cost analysis.
In future LCA will be the standard tool for product development.

Inpuls
Outputs

Raw material acquisition Water emmisions

Rawmaterial
Processing and manufacturing
atm emmision
Energy global warming
ozone depletic
Distribution/Transportation
smog

Use/Maintenance/Re-use Solid waste

Hazardous
Recycle liquid waste

Radioactivity
Waste management

Usable product

Fig. 5.11.2: Framework for developing a lifecycle Analysis

Syllabus Topic: Weighted Sum Assessment Methods (Numerical)

5.12 Weighted Sum Assessment Methods (Numerical)

(SPPU - May 16)
a.5.12.1 What is lifecycle assessment? Explain any one method in detail.
(Ref. Secs. 5.11 and 5.12)
Q.5.12.2 Discuss weighted sum Assessment Methods for life cycle assessment. (Ref. Sec. 5.12) May 16, 8Marks
While studying different methods of assessment of environmental (5Marks)
relative importance or more advanced approach is to complete a full impact. One may have more
quantitative approach or
life cycle assessment
the material usage and waste generation of each which accesses the impact of
stage in the product life cycle.
Instead of performing full lifecycle of assessment one
may have inventory
average impact weightings. parts used in a product and
weight them by
That one may
is break the product down into quantities of materials in the
Then one might establish environmental or aierent
product by weight,
impact
anproximates the life cycle stages of the product as an average
materials by weight and sum
typical use for each material this score. This process
Product Design and Development (SPPU) 5-19
Impact Effect
Design forX
Damage Valuation Result
Ozone layer depletion
CFC
Pb
Heavy metale
Cd
Carcinogenics Fatalities
PAH
Dust Summer smog
VOc
Winter smog
DDT Health Subjective Eco-indicator
impalrment damage
cO2 Pesticides assessment
value

SO2
Greenhouse effect
NO, Ecosystem
Impalrment
P Acidification
Eutrophication
Fig.5.12.1
Table 5.12.1 Development of Weighting for the Eco indicator 95
Environmental effect Weighting Factor Criteria
Grcenhouse effect 25 0.1YC rise every 10 years 5% ecosystem degradation.
Ozone Layer Depletion 100 Probability of 1 fatality per year per million inhabitants.
Acidification 10 5% ecosystem degradation.
Rivers and lakes degradation of an unknown number of
Eutrophication
aquatic ecosystems (5% degradation).
Occurrence of smog periods health complaints particularly
Summer Smog 2.5 amongst asthma patients and the elderly prevention of
agricultural damage.
Occurrence of smog periods, health complaints particularly
Winter smog 5
amongst asthma patients and the elderly.

Pestic 23 5% ecosystem degradation.

Airborne heavy metals 5 Lead content in children's blood, reduced life expectancy and
learning performance in an unknown number of people.
Cadmium content in rivers ultimately also impacts on people
Waterborne heavy metals 5
(see airborne).
Carcinogenic substances 10 Probability of fatality per year per million people.
One such a approach was developed in Europe at Netherlands called as eco-indicator 95. It was developed by ministry
of housing, spatial planning and the environment.
This eco-indicator system provides weightings by mass for material, treatment processes, transport processes, energy
generation processes and disposal scenarios.
As shown the figure the weightings are based on a valuation of damage to public health and to the eco system through
contribution to the several effects, such as ozone layer depletion, smog and so forth. The actual effects which are

considered and from what impact sources are shown in the Table 5.12.1.
As eco indicator was developed in Europe it is based on average European values as shown in figure and table. For this
the processes that describe material production, treatments, transportation and energy generation.
Therefore the application of the eco indicator to non European regions will not be entirely appropriate. For example

product factors that increase acid rain are over weighted for many regions in the united states.
 Design for X
4Product Designand Devoloprment (SPPU) 6-20
environmental iriendiness of different
On the other hand this tool is reasonable and provides indications of relative
design soenarios
establish the mass of component materials in the product.
The eco-indicator system operates by having the analyst first cvaluate the product, Then different
used to
their means of prodiuction and the mean of disposal. A workshect is

weighting vales are used

we should estimate how long
numerical analysis. Particularly
Other life cycle data must be estimated to complete the
how it is disposed.
the product is used, how it is delivered to thc consumer and
that can be uscd as a first approximation of the actual useful life
Table 5.12.2 shows a list of typical product life spans

for different product.

Without Recycling
Table 5.12.2: Common Product Life Cycles
Common Product Life Cycles Without Recycling
Product type Useful life (years)

Noveltics
Photographic film

Disposable dinnerware and hospital goods

1-2
Packaging8
Construction film 2

Footwear 2
4
Apparel
Houschold goods 5

Toys 5

Jewellery
Saucepans
Sporting goods 7
Domestic appliances 7-10

Luggage 10
Cameras 10

Furniture 10
Motor vehicles 10
Electrical goods 10-15
Hardware 15
Aircraft 15
Wire and cable 15-30
Consuruction 25-40
Machinery 30
Delivery can be estimated based on the source, domestic or international. Disposal should simply be approximated as
landfGll. unless either the material is very hazards and laws apply to its disposal or the material is valuable.
Table 5.12.3 shows Sumnary of Kelevant 10-ndicalor Data and its impact on environment.
very
Product Design and Development (SPPU) 5-21
Design for X
Table 5.12.3:
Summary of Relevant Eco-Indicator Data
Category Score in Micropoints Percentage of total Damage
Production and Processes 7291 85%
Use
Life Cycle Phase 1018 12%
Disposal 270 3%
Total Score
8579 100%
Copper (Whole product) 4893 57%
Plastics 834 10%
Impact by Material Non-Copper Metals 1464 17%
Other materials 320 4%
Subtotal 7512 88%
Motor 4538 53%
Power use of motor 1018 12%
Cord 1768 21%
Impact by Phase Base and housing 779 9%

Packaging8 202 2%
Other 250 3%
Total Impact 8579 100%
A typical example of Eco Indicator worksheet is as shown in the Fig. 5.12.2.

Metals Production
Material or process Amount Indicator Result
secondary Steel 4.1 4.1
Aluminium 6 85 510
Secondary copper 100

Material

Amount in your d e s i g n - kg

Indicator value for the material, per k9

Material contribution to your design

514.1
Total

Fig. 5.12.2: Eco-Indicator 95

Worksheet
 esign for X
5-22
Product Designand Development (SPPU)
Failure Mode Effect Analysis
Syllabus Topic: Design

(DFMEA)
5.13 Design Failure Mode Effect Analysis (5 Marks)
Q.5.13.1 Explain Design Failure Mode EffectAnalysis. (Ref.Sec.5.13 functional parts of product and study of impact of those
It is a technique of predicting the failure criterias of major
criterias of failure on product.
failure mode effect analysis.
This technique is known as FMEA i.e. considers. how frequentty
it is occurring and how it
of their effects. It also
It classifies failures by considering extent
can be detected.
It is adopted widely as advanced product quality planning.
reasons which have been considered and
and their associated
It is the study of potential failure modes of product
addressed in the product design.
Here we come across some questions like

(a) Where it can be go wrong?

(b) Where we are finding the variation from?
(c) How we can control it ?
We are having some types of FMEA:
(a) Design (DFMEA) i.e. Design failure mode effect analysis.
(b) Process (PFMEA)
What will we get by performing DFMEA ?
We can identify or detect the ways of failure of product design in its early stage. e can take preventive action or can

go forredesign before risk.

Which will result in reduction of warranty, production and
By doing this we can have enhanced product reliability.
development cost? We get higher customer satisfaction. Areas for analysls In DFMEA
5.13.1 DFMEA Process Process.

DFMEA considers failure due to several reasons to decide why the loss of i) Mode of failure
desired functions has occurred under the given set of conditions. We have four areas
for analysis. i) Efect of failure
Mode of failure
ii) Causes of tailure
The path in which we are observing the failure.
ii) Effect of failure iv) Extent or severity

The immediate effect of failure on the functionality or operation of product. Fig. C5.1
iii) Causes of failure
Things which are responsible for process and which leads to failure (i.e. design defect, process, quality)
iv) Extent or severity
These effects of failure modes are considered tor worst case outcomes or result as degree of injury, damage to tne
property and harm that ultimately can occur.
After performing above analysis we go for determination of RPN (Risk
priority number) which is calculated as
Extent or severity of effect of failure (S) : For this we apply a value on a scale of 1
(LOW) to 10 (HIGH).
the failure occur: (0)
How frequently
For this we apply a value on scale of 1 (infrequent) to 10 (frequent)
Preventability or detection (P):
For this we apply a value on scale of . (highly detectable) to 10 (not detectable)
 =
Product Design and Development (SPPU) 5-23
Design forTX
Finally we have formula-

Risk Priority Number (RPN) =

Product S, O and P
SxOxP
So this product S x O xP for RPN results as 1 (Low Risk) to 1000 (High Risk). Thus by studying this users can analyze
what is acceptable and unacceptable.
Objectives of DFMEA

Guide a sequential and logical design process.

Detect and reduce risk in design.
Prepare a document for design and development.
Proper justification of design activities.
A platform for continuous product improvement.
Scope and responsibilities of DFMEA
It is a function of team or requires team work.
Active participation of all team members is required.
It requires input from all the members of technical as well as non technical field.

It is not a single meeting activity, it's a continuous process.

It must include components, systems and subsystem of the product design.

What is the input to DFMEA ?

1. Requirements of product design

Legal, technical and design requirement of document.
2 BOM (bill of Materials)
Components, list of components as supplied by customer.
3. Definition of product
Simulations, animations, sketches and conceptual sketches, designs.
Components, system descriptions.
4. Previous history of experiences
and guide lines.
Customer and supplier inputs Design standards
-

Output of DFMEA

i) Risk Priority Number (RPN)

characteristics of product.
i) Detection of significant and critical

Benefits of FMEA

i) It avoids failures before they happen

and designs.
i) It detects critical facts about processes
control is needed.
ii) It identifies where the focus and
continuous improvement.
iv) It is essential for quality and
v)Itreduces final cost and scrap.
vi) t prevents field failure.

vii) It prioritizes the risk.

 Designffor
Product Design and Development (SPPU) 5-24
Diagram product cycle with DFMEA

Requirements
of
customer
DFMEA
.Where and what can go wrong?
know?
.What should we
What they need exactly?
What can occur?
Design critical?
What and where it can be

reduced?
How the final cost can be

How we can make the things better?

Production How we learnt?

Customer
satisfaction

Fig. 5.13.1

5.14 Exam Pack (University and Review Questions)

Syllabus Topic: Design for Manufacture

a. 1 Explain the guidelines for design for manufacture. Design for assemble and design for environment in detail.
(ReferSections 5.1, 5.1.1, 5.2, 5.7and 5.7.1) (Dec. 15, 16 Marks)

a.2 Explain the guidelines of design for manufacture in detail. (ReferSections 5.1 and 5.1.1) (May 16, May 17, 6 Marks)
Syllabus Topic: Design For Assembly (DFA)
Q. 3 Explain the guidelines for design for manufacture. Design for assemble and design tor environment in detail.
(ReferSections 5.1, 5.1.1, 5.2, 5.7 and 5.7.1) (Dec. 15, 16 Marks)
Q.4 Explain the guidelines for design for assemble. (Refer Section 5.2) (Dec. 16,6 Marks)
Syllabus Topic: Design for Robustness
5 Discuss design for robustness in detail. (Refer Section 5.3)
(May 16,8 Marks)
6 What are guidelines for design for robustness? Discuss.
(Refer Section 5.3) (Dec. 16,5 Marks, May 17, 4 Marks)
Q.7 Explain guidelines of design for robustness and safety.
(Refer Sections 5.3, 5.4, 5.4.1 and 5.4.2)
(May 18,8 Marks)
Syllabus Topic: Designfor Safety
Q.8 What are guidelines for design for safety ? Discuss and elaborate.
(Refer Sections 5.4, 5.4.1 and 5.4.2)
(May 17,5 Marks)
4ProductDesign and Development (SPPU) 5-25
Design for X
a.9 Explain guidelines of design for robustness and safety.
(Refer Sections 5.3, 5.4, 5.4.1 and 5.4.2)
(May 18, 8 Marks)
Syllabus Toplc: Design for Reliability
.10 What are the guidelines for design for reliability? Discuss in detail. (Refer Section 5.5) (5 Marks)
Syllabus Topic: Design for Environment (DFE)
a.11 Explain the guidelines for design for manufacture. Design for assemble and design for environment in detail.
(Refer Sections 5.1, 5.1.1, 5.2, 5.7 and 5.7.1)
(Dec. 15,16 Marks)
Q.12 Discuss guidelines for design for environment and materials in detail.
(Refer Sections 5.7 and 5.7.1) (May 18, 8 Marks)
Q.13 What are the objectives and need of design for environment? (Refer Section 5.7)
(6 Marks)
a.14 Explain the design for recycling. (Refer Section 5.7.2) (5 Marks)
Q.15 Explain the design for remanufacturing. (Refer Section 5.7.3) (5 Marks)
Syllabus Topic: Design for Piece Part Production
a. 16 Explain the guidelines for design for casting. (Fefer Section 5.8.1) (May 17, 5 Marks)

Q. 17 Discuss guidelines of design for casting and forging. (Refer Sections 5.8.1 and 5.8.2) (May 18, 8 Marks)

a. 18 Explain the concept of piece part production. (Refer Section 5.8) (5 Marks)
Syllabus Topic: Manufacturing Cost Analysis
Q.119 Discuss in detail manufacturing cost analysis. (Refer Section 5.9) (May 17, 6 Marks)

Q. 20 Explain manufacturing cost analysis. Explain stepwise procedure for estimation of cost.
(Refer Section 5.9) (May 18, 8 Marks)

Syllabus Topic: Local, Regional and Global Issue

a.21 What are local and regional issues for environment ? Elaborate. (Refer Section 5.10) (Dec. 15, 8 Marks)

Q. 22 Discuss various regional and global issues of environment pollution.

(ReferSection 5.10) (May 16, 8 Marks, May 17, 6 Marks)

Syllabus Topic: Basic Life Cycle Assessment-Basic Method

o. 23 What is lifecycle assessment? Explain any one method in detail. (Reler Sections 5.11 and 5. 12 (May 16, 8 Marks)

Syllabus Topic : Weighted Sum Assessment Methods (Numerical)

method in detail.
a. 24 What islifecycle assessment? Explain any one
(ReferSections 5.11 and 5.12) (May 16, 8 Marks)

Q.25
Discuss weighted sum Assessment Methods for life cycle assessment. (Refer Section 5.12) (5 Marks)

Syllabus Topic: Design Failure Mode Effect Analysis

Q. 26 Explain Design Failure Mode Effect Analysis. (Refer Section 5.13) (5 Marks)