Rule Based Methods in Concurrent Engineering -4

Design for Assembly

Design for Assembly

Definition: A process for improving product design for easy and low-cost assembly, focusing on functionality and on assembly concurrently. Aim: To simplify the product so that the cost of assembly is reduced. Initially developed by Geoffrey Boothroyd in mid 1970s.

Assembly Methods

Manual Assembly Automatic Assembly

-Workers manually -Special purpose assembly assemble the product or machines components of a product -Assemble one specific -Hand tools are used product -Flexible -Problem when production increases -Labor costs

Robotic Assembly
-Programmable assembly machines -Use robotic assembly systems -Controlled by PLC or computer

Assembly Methods
Relative costs of different assembly methods by type and production volume.

Evaluation methods for DFA

Boothroyd-dewhurst method

Based on two principles

the application of criteria to each part to determine if it should be separate from all other parts. estimation of the handling and assembly costs for each part using the appropriate assembly process.

Lucas method (early 1980s by Lucas Corp, UK)

Boothroyd-dewhurst method

Relies on an existing design which is iteratively evaluated and improved. Steps:

Select an assembly method for each part Analyze the parts for the given assembly methods Refine the design in response to shortcomings identified by the analysis Loop to step 2 until the analysis yields a sufficient design

Worksheet for analysis

Sample Boothroyd-Dewhurst DFA worksheet Name of assembl y

i*

Part ID#

# of Consecutive identical operations

2-digit handling code

Manual handling time/ part

2-digit insertion code

Manual insertion time/ part

Operation time (bd+f)

Operation cost

Essential part?

Totals go here ->

Tm=

Cm=

Nm=

Boothroyd-dewhurst method

Parts are evaluated as to whether it is really necessary (in the assembly) by asking three questions:

does the part move relative to another part? are the material properties of the part necessary? does the part need to be a separate entity for the sake of assembly?

All parts are then evaluated to obtain the minimum number of theoretically needed parts, denoted by Nm.

Boothroyd-dewhurst method

Boothroyd-dewhurst method

Boothroyd-dewhurst method

Design efficiency = (Assembly time for a part x Nm) / Tm

Lucas method

Boothroyd-Dewhurst method is based on timing each of the handling and insertion motions Lucas method is based on a "point scale" which gives a relative measure of assembly difficulty Lucas method is based on three separate and sequential analyses

Functional analysis Feeding analysis Fitting analysis

Functional Analysis

The components of the product are reviewed only for their function and divided into two groups A and B

Group A - those that are essential to the product's function Group B - those that are not essential to the product's function

Design efficiency = A / (A+B)x100% Typically, a design efficiency of 60% is targeted for initial designs.

Feeding/Handling Analysis

both the part handling and insertion times are examined (similar to Boothroyd-Dewhurst analysis) Component is awarded a score on its ease of handling Feeding Ratio= (Total feeding/handing index) Number of essential components Ideal feeding ratio 2.5

Lucas DFA method - Manual Handling Analysis Handling Index = A+B+C+D B. Handling difficulties All that apply Delicate A. Size & Weight of Part One of the following Very small - requires tools 1.5 Flexible Sticky Tangible Convenient - hands only Large and/or heavy requires more than 1 hand 1 1.5 Severely nest Sharp/Abrasive Untouchable Gripping problem / slippery Large and/or heavy requires hoist or 2 people 3 No handling difficulties C. Orientation of Part One of the following: Symmetrical, no orientation req'd End to end, easy to see 0 D. Rotational Orientation of Part One of the following Rotational Symmetry Rotational Orientation, easy to see Rotational Orientation, hard to see 0 0.2 0.4 0 0.4 0.6 0.5 0.8 0.7 0.3 0.5 0.2

0.1

End to end, not visible

0.5

Fitting Analysis

Need to know the proposed assembly sequence Relative difficulty in assembling the complete product is determined.

Whether the component needs to holding in a fixture The assembly direction Alignment problems Restricted vision Required insertion force

Fitting index =Total fitting index/No. of essential components

Lucas DFA method - Manual Fitting Analysis Fitting Index = A+B+C+D+E+F A. Part Placing and Fastening One of the following Self-holding orientation Requires holding Plus 1 of the following Self-securing (i.e. snaps) Screwing Riveting Bending 1.0 2.0 1.3 4.0 4.0 4.0 D. Access and/or Vision One of the following Direct Restricted 0 1.5 B. Process Direction One of the following Straight line from above Straight line not from above Not a straight line 0 0.1 1.6

C. Insertion One of the following Single Multiple insertions Simultaneous multiple insertions 0 0.7 1.2

E. Alignment One of the following Easy to align Difficult to align 0 0.7

F. Insertion Force One of the following No resistance to insertion Resistance to insertion 0 0.6

Manufacturing Analysis

Find the cost of manufacturing each component Not a true cost but guide the designer by giving a relative measure of manufacturing cost