Design for manufacturability and assembly. Practical Design for Manufacturability and Assembly 2022-11-16
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Design for Manufacturability and Assembly (DFMA) is a systematic approach to designing products that are easy to manufacture and assemble. The goal of DFMA is to reduce production costs and increase efficiency by making the manufacturing process as smooth and straightforward as possible.
One important aspect of DFMA is the use of standard, off-the-shelf components whenever possible. This allows manufacturers to take advantage of economies of scale and reduces the need for custom tooling and fixtures. Standard components are also often easier to source and replace, which can be important for maintaining a consistent production process.
Another key aspect of DFMA is the use of modular design. Modular design involves breaking a product down into smaller, interchangeable components that can be easily assembled and disassembled. This allows manufacturers to build products in a flexible and efficient manner, as they can easily swap out components as needed without having to redesign the entire product. Modular design also makes it easier to repair and upgrade products, as individual components can be replaced without having to throw away the entire product.
DFMA also involves careful consideration of the assembly process. This includes designing components and assemblies that are easy to handle and manipulate, using clear and intuitive markings and instructions, and minimizing the number of required steps. By streamlining the assembly process, manufacturers can reduce the risk of errors and increase the speed of production.
In addition to these considerations, DFMA also involves designing for ease of testing and inspection. This includes designing in features that allow for easy access to test points, as well as ensuring that components are easy to inspect for defects. By designing for testability and inspection, manufacturers can reduce the time and cost of quality control processes.
Overall, DFMA is a critical aspect of product design that can have a significant impact on the efficiency and cost-effectiveness of the manufacturing process. By designing products that are easy to manufacture and assemble, companies can reduce production costs, increase efficiency, and improve the overall quality of their products.
Design for Manufacture and Assembly
Consider various potential features and material options. Industrial Design Industrial design covers the tangible translation of design research inputs into industrial design outputs. Only a few authors have investigated the adoption of enabling technologies for Industry 4. In: Proceedings of the Design Society: DESIGN Conference, vol 1. In addition, there will be a brief demonstration of computer software tools, which simplify the DFM+A analysis.
Design for Manufacturability and Design for Assembly
Some other departments involved with the product include Quality inspection , Purchasing material procurement , and even Marketing. ASME Appl Mech Rev 39 9 :1356—1364. Those experts use tools and methods like operational standards, manufacturing guidelines, business excellence guidelines, which in turn drive process efficiencies and reduce the pain points along this journey. One need only look at early 2000s Ford and GM vehicles to find broken plastic door panel clips all over the place. Since this review is focused on DFMA methods for mechanical products, most of the presented case studies refer to the mechanical and electro-mechanical fields.
No methodology should be used outside of the broader context of the full product development cycle. This prevents distortion or damage during the manufacturing process, thus reducing waste of time and materials. Inertia is the basis of non-linear costs in product development As more prototypes are developed and the design team begins to see a clearer picture of the final design, inertia builds. Features like conductivity, malleability, weldability, ductility, luster, corrosion resistance, impact the manner in which they may be successfully utilized. On the other hand, feature-based DFMA indices rely on tables to convert assembly-related features into scores. According to the articles reviewed, it is worth noting that performing DFMA analysis early in the design process could result in benefits such as increased solution space. At some point you need to fill in your imperfect information and begin designing for a particular manufacturing capability.
Finally, due to the high number of articles found, no other sampling techniques e. But it's more important than ever in these competitive times when speed and efficiency are essential for maintaining profitability. In: Proceedings of the Design Society: DESIGN Conference, vol 1. Features can be added into parts that allow them to self align such that additional assembly fixtures can be eliminated. This course is most effective when attended by product development team members; however, this is not a requirement for attendance.
Design for Manufacturability and Assembly DFM DFMA Premium Resources
Approximately 70% of product cost is set during the design phase, so it is incumbent on design engineers to understand how design decisions propagate downstream. It reduces the wastage of materials, motion, inventory and overprocessing. Moreover, journals present more structured and mature research than conference proceedings. One of these parts may function equally as well or there may be a non-critical specification e. For instance, the design structure matrix DSM is a well-known tool to represent product architectures. DFMA supports faster lead times by reducing reworks and waste, which can also One of the biggest obstacles to overcome with sheet metal design is that modeling is based on an ideal state where everything is nominal and where execution of the design is assumed to be performed by perfect equipment and operators. DFMA can help us leverage the advantages of both these methodologies without the disadvantages of either.
Removing a fastener entirely will obviously reduce assembly cost, but it should be done with a good understanding of how product performance will be impacted. Looser tolerances allow you to reduce part cost by increasing production speed, lengthening tool life, simplifying quality control and reducing scrap rate. The Research Topic Share RTS is computed considering the overall number of papers divided for the number of papers of the last decade for a given topic. Products analysed with DFMA methods are varying from sub-assemblies of a car i. Because of this, design for manufacturability is a crucial step and has the ability to eliminate the need for costly changes before entering full production.
A method is considered quantitative when it provides a numerical evaluation e. Using some of the previous design rules as a framework, the designer needs to creatively develop design alternatives. From the performed review, a dedicated software system is the main used tool, followed by spreadsheets and graphs see Fig. Read on for some innovative tips as well as reminders of concepts of which we are aware, but sometimes neglect to consider. Design automation tools can assist in the economic development of multiple design alternatives as well as the evaluation of these alternatives.
Standardizing on a few types of fasteners limits the number of unique tools required during assembly. In the past few decades, research into design thinking has engendered a new wave of methodologies in product design and manufacturing processes. A costlier material that will hold up may represent overall savings when compared to a less sturdy material that will result in rejected parts and waste. Another interesting area of investigation regards the type of DFMA method versus the design phase at which it is used. He holds a bachelor's and master's degree in engineering from Wayne State University.